4526 R430 01

Process Simulation Fundamentals
Process Modeling using

UniSim Design
PDS-4526
2013 Honeywell All rights reserved.

UniSim is a U.S. registered trademark of Honeywell International Inc
4526.R430.01
Copyright
The information in this training course is subject to change over time. Honeywell may make changes
to the requirements described. Future revisions will incorporate changes, including corrections of
typographical errors and technical inaccuracies.
For further information please contact:
Honeywell
5925 Centre Street SE
Calgary, Alberta, CANADA
T2H 0C2
Telephone: 1-866-392-8748
Email: unisim.support@honeywell.com
Web: www.honeywellprocess.com/software
http://unisim.supportportal.com
Copyright Honeywell 2013. All rights reserved.

UniSim is a U.S. registered trademark of Honeywell International Inc.
Prepared in Belgium, Canada, Hungary and the United Kingdom.
Module Index
1. Getting Started
2. Propane Refrigeration Loop
3. Refrigerated Gas Plant
4. NGL Fractionation Plant
5. Oil Characterization
6. Two Stage Compression
7. Acid Gas Sweetening with DEA
8. Natural Gas Dehydration with TEG
9. Reporting with UniSim Design
QA. Answers to Questions
Getting Started 1.1
1. Getting Started

4526.01.R430.01
1.2 Getting Started
1.2
Getting Started 1.3
Workshop
The Getting Started module introduces you to some of the basic
concepts necessary for creating simulations in UniSim Design. You
will use UniSim Design to define three gas streams to be used as
feeds to a gas plant. In addition, you will learn how to determine
properties of these streams by using the Phase Envelope and the
Property Table utilities.
Learning Objectives
Define a fluid package (property package, components,
hypotheticals)
Add streams
Understand flash calculations
Attach stream utilities
Customize the Workbook
1.3
1.4 Getting Started
Simulation Basis
Manager
UniSim Design uses the concept of the fluid package to contain all
necessary information for performing flash and physical property
calculations. This approach allows you to define all information
(property package, components, hypothetical components, tabular
data, interaction parameters, reactions, etc.) inside a single entity.
There are four key advantages to this approach:
All associated information is defined in a single location,
allowing for easy creation and modification of the data.
Fluid packages can be saved as completely defined entities
for use in any simulation.
Component lists can be saved separately from the Fluid
Packages as completely defined entities for use in any
simulation.
Multiple Fluid Packages can be used in the same simulation,
however, are all defined inside the common Basis Manager.
The Simulation Basis Manager is a property view that allows you to
create and manipulate multiple fluid packages or component lists in
the simulation. The opening tab of the Simulation Basis Manager
allows for the creation of component lists which are independent
from fluid packages but can be associated with the individual fluid
packages in the case.
1.4
Getting Started 1.5
The first tab of the Basis Manager allows you to manage the
component list(s) used in your case. There are a number of
buttons available:
Figure 1
Button Description
View Allows you to access the property view for the selected
Component List.
Add Allows you to create a Component List.
Note: Component Lists can be added via the Fluid Package
property view.
Delete Removes the selected Component List from the simulation.
Copy Makes a copy of the selected Component List.
Import Allows you to import a predefined Component List from disk.
Component Lists have the file extension (.cml).
Export Allows you to export the selected Component List to disk. The
exported Component List can be retrieved into another case, by
using the Import function.
Refresh Updates the pure component properties from the database.
Re-import Allows you to re-import a cml file.
You can use the Ctrl B hot key to re-enter the Simulation Basis
Manager at any point or click the Basis Environment icon from the
Basis Environment icon tool bar.
1.5
1.6 Getting Started
Inside the Current Fluid Packages group, there are a number of

buttons:
Figure 2
Button Description
View This is only active when a Fluid Package exists in the case. It
allows you to view the property view for the selected Fluid
Package.
Add Allows you to create and install a Fluid Package in the simulation.
Delete Removes the selected Fluid Package from the simulation.
Copy Makes a copy of the selected Fluid Package. Everything is
identical in the copied version except the name. This is useful for
modifying Fluid Packages.
Import Allows you to import a predefined Fluid Package from disk. Fluid
Packages have the file extension (.fpk).
Export Allows you to export the selected Fluid Package to a disk. The
exported Fluid Package can be retrieved into another case by
using the Import function.
1.6
Getting Started 1.7
Defining the Simulation

Basis
Add a Property Package
1. Start a new case by selecting the New Case icon.
2. Go to the Fluid Pkgs tab and create a fluid package by clicking
New Case icon
the Add button.
3. Scroll down the list and select the Peng-Robinson Equation of

State model.
Figure 3
You can select the

EOSs radio button in
the Filter box, and then
select Peng-Robinson;
however, it is not
necessary to select
EOSs after you have
selected Peng-
Robinson.
4. Change the Name from the default Basis-1 to GasPlant using

the Name input box at the bottom of the window.
5. Click the View button in the Component List Selection section
of the Set Up tab. This will allow you to add components to
the Component List that is now associated with the GasPlant
fluid package.
1.7
1.8 Getting Started
Add Components
You can select components for your simulation using several
methods.
To use... Do this...
Component 1. Using the scroll bar for the main component list, scroll through
List the list until you find the desired component.
2. To add the component, either:
Press the ENTER key.
You can add a range of Click the Add Pure button.
components by Double-click on the component to add it to your simulation.
highlighting the entire
range and clicking the Match Cell 1. Select one of the three name formats, SimName, Full
Add Pure button. Name/Synonym, or Formula by selecting the corresponding
radio button.
Standard Windows list
conventions (Shift = 2. Click in the Match input field and enter the name of the
Select Range, Ctrl = component. As you start to type, the list will change to match
Multi-Select) also work. what you have entered.
3. Once the desired component is highlighted, either:
Click the ENTER key.
Click the Add Pure button.
Double-click on the component to add it to your simulation.
Filter 1. Ensure the Match cell is empty, and click the View Filter
button.
2. Select the Use Filter checkbox to display the various family
filters.
3. Select the desired family (e.g. Hydrocarbons) from the list of
Family Filters to display only that type of component.
4. Use either of the two previous methods to then select the
desired component.
6. Select the following library components, using one of the

methods described above:
Nitrogen i-Butane
H2S n-Butane
CO2 i-Pentane
Methane n-Pentane
Ethane n-Hexane
Propane H2O
1.8
Getting Started 1.9
Figure 4
7. Click on the Hypo Components\Traditional item in the Add

Component box.
Figure 5
When you click the

Quick Create a Hypo
Component button,
UniSim Design adds a
hydrocarbon class hypo
by default.
If you want to add a
hypo from another
class, click the Hypo
Manager button and
then in the view that
appears, click the View
Group button. This will
open the Tabular Hypo
Group input window,
where you can add non-
hydrocarbon class 8. Click on the Quick Create a Hypo Component button to
hypotheticals. create a hypothetical component.
A hypothetical component can be used to model non-library
components, defined mixtures, undefined mixtures, or solids. You
will be using a hypothetical component to model the components in
the gas mixture heavier than hexane.
9. In the hypo component view, click on the ID tab and in the
Component Name cell type C7+.
1.9
1.10 Getting Started
Figure 6
UniSim Design always

places an * after a
hypo name so it can be
distinguished from
library components.
Since you do not know the structure of the hypothetical component

and you are modeling a mixture, the Structure Builder will not be
used.
10. Click on the Critical tab. The only property supplied by the lab
for the C7+ component is the Normal Boiling Pt; enter a value
of 110C (230F).
1.10
Getting Started 1.11
11. Click the Est Unknown Props button to estimate all the other
properties and fully define the hypothetical component.
Figure 7
The minimum
information required for
defining a hypo is the
Normal Boiling Pt or
the Molecular Weight
and Ideal Liq Density.
12. When the hypo component has been defined, return to the
component list by closing the hypo component C7+* view.
13. Add the hypo component to the Selected Components list by

selecting it in the Available Hypo Components list and then
clicking the Add Hypo button.
Figure 8
When a component is
added to the Selected
Components list it
appears above the
currently selected
component.
You can use the Sort
List button to order the
Component List.
1.11
Every hypo you create is part of a Hypo Group. By default, this

hypo is placed in HypoGroup1. You can add additional groups and
move hypo components between groups. This is done on the
Hypotheticals tab of the Simulation Basis Manager.
Compare the properties of C7+ with C7 and C8.
C7+ C7 C8
Normal Boiling
Point
Ideal Liquid
Density
Molecular
Weight
You have now finished defining the fluid package. You can view
the Peng-Robinson binary coefficients for your selected
components by selecting the Binary Coeffs tab on the Fluid
You will need to add
Package tab.
components C7 and C8
to the component list in
order to view their
properties. Ensure that
you delete them once
this exercise is finished.
1.12
Exporting Fluid
Packages
UniSim Design allows you to export fluid packages for use in other
simulations. This functionality allows you to create a single
common fluid package which you may then use in multiple cases.
14. On the Fluid Pkgs tab, highlight the GasPlant fluid package.
Figure 9
15. Click the Export button.

16. Enter a unique name (4526.01.GasPlant.fpk) for the fluid
package and click the Save button.
1.13
Figure 10
UniSim Design will

automatically add the
file extension .fpk when
it saves your fluid
package.
The file is automatically
saved to the \Paks
folder of the
UniSim Design folder in
My Documents.
Now that the fluid package has been defined, you can start building
the simulation. Click the Enter Simulation Environment button
Enter Simulation on the Simulation Basis Manager window to begin building the
Environment icon
simulation.
1.14
Building the Simulation

When you build the simulation, you will:
Select a unit set
Add streams, and specify them
Attach utilities
Select a Unit Set

In UniSim Design, it is possible to change the unit set used to
display its different variables.
1. From the Tools menu, choose Preferences.
2. Click on the Variables tab.
Figure 11
3. Select the SI unit set.

4. Close this view to return to the simulation.
1.15
Adding Streams
In UniSim Design, there are two types of streams, Material and
Energy. Material streams have a composition and parameters
such as temperature, pressure, and flow rates. They are used to
represent process streams. Energy streams have only one
parameter: heat flow. They are used to represent the duty
supplied to or produced by a unit operation.
There are a variety of ways to add streams in UniSim Design.
To use Do this...
this...
Menu Bar From the Flowsheet menu select Add Stream.
or
Press the F11 Hot Key.
The Stream property view opens.
Workbook Open the Workbook and go to the Streams tab. Type a stream
name into the **New** cell.
Object From the Flowsheet menu, select Open Object Palette or press
Palette F4 to open the Object Palette. Double-click on the stream icon.
In this case, you will add three streams to represent three different
gas wells. Each stream will be added using a different method of
installation.
Adding a Stream from the Menu

Bar
To add a stream using the F11 hot key:
1. Press F11. The stream property view appears. If the stream
property view is not displayed, double-click on the newly
created stream (from the PFD) to bring up the property view.
1.16
Figure 12
2. Highlight the Stream Name cell. Change the stream name by

typing in a new name: GasWell 1 and then press ENTER.
Entering Stream Compositions

Stream compositions are set via the Input Composition for
Stream window but there are two different ways to access it.
On this page... Do this...
Conditions Double-click on the Molar Flow cell to enter mole
fractions.
or
Double-click on the Mass Flow cell to enter mass
fractions.
or
Double-click on the Std Ideal Liquid Volume Flow
cell to enter liquid volume fractions.
The Input Composition for Stream view appears.
Composition Click the Edit button.
The Input Composition for Stream view appears.
3. If the Input Composition for Stream view is not already

open, double-click on the Molar Flow cell.
1.17
Figure 13
The Normalize button

sets any <empty>
cells to 0 and adjusts
the entered component
fractions so that they
sum to 1.
The Equalize
Composition button
sets all compositions to
1.
4. Make sure the Mole Fractions radio button is set and enter the
following compositions:
For this component... Enter this mole fraction...

Nitrogen 0.0002
H2S 0.0405
CO2 0.0151
Methane 0.7250
Ethane 0.0815
Propane 0.0455
i-Butane 0.0150
n-Butane 0.0180
i-Pentane 0.0120
n-Pentane 0.0130
n-Hexane 0.0090
Take care when closing
the Input C7+* 0.0252
Composition for
Stream view. H2O 0.0000
Changes are only saved
when OK is pressed. 5. Click the OK button when all the mole fractions have been
Any non-normalized
compositions are
entered
automatically 6. Close the Stream property view.
normalized when OK is
pressed.
1.18
Adding a Stream from the

Workbook
To open the Workbook, click the Workbook icon on the tool bar.
Workbook icon 1. Enter the stream name, GasWell 2 in the **New** cell.
2. Enter the following Molar compositions:

Nitrogen 0.0025
H2S 0.0237
CO2 0.0048
Methane 0.6800
Ethane 0.1920
Propane 0.0710
i-Butane 0.0115
n-Butane 0.0085
i-Pentane 0.0036
n-Pentane 0.0021
n-Hexane 0.0003
C7+* 0.0000
H2O 0.0000
3. Click the OK button to close the Input Composition for

Stream view.
Adding a Stream from the Object

Palette
1. If the Object Palette is not open on the Desktop, press F4 to
open it.
Material Stream icon
(Blue) 2. Double-click on the Material Stream icon. A new stream is
added to the flowsheet. Double-click on the new stream to
access the Stream property view.
3. Change the name of the stream to GasWell 3.
4. Double-click on Molar Flow.
5. Enter the following stream compositions:
1.19

Nitrogen 0.0050
H2S 0.0141
CO2 0.0205
Methane 0.5664
Ethane 0.2545
Propane 0.0145
i-Butane 0.0041
n-Butane 0.0075
i-Pentane 0.0038
n-Pentane 0.0037
n-Hexane 0.0060
C7+* 0.0090
H2O 0.0909
4. Click OK to close the Input Composition for Stream view.

You can use one of several different methods to save a case in
UniSim Design:
From the File menu, select Save to save your case with the
same name.
Save Case icon
From the File menu, select Save As to save your case in a
different location or with a different name.
Click the Save Case icon on the tool bar to save your case
with the same name.
5. Click the Save Case icon, since this case doesnt yet have a file
name, enter one (For example 4526.01.GettingStarted.usc)
Save your case!

Save your case often to
avoid the possibility of
losing information.
1.20
Changing Units for a

Specification
To change the units for a specification, simply type the numerical
value of the specification and press the space bar, or click on the
unit drop-down list. Choose the units for the value you are
providing. UniSim Design will convert the units back to the default
units.
Figure 14
You can scroll through

the unit list by starting
to type the units, by
using the arrow keys,
or by using the scroll
bar.
To edit an existing
value press F2 or use
the small vertical bar to
the left of the cell.
1.21
Flash Calculations
UniSim Design can perform several types of flash calculations on
streams. The most common types are Pressure-Temperature
(P-T), Vapour Fraction-Pressure (Vf-P), and Vapour
Fraction-Temperature (Vf-T). Once the composition of the
stream and two of either, temperature, pressure or vapour
fraction, are known, UniSim Design performs a flash calculation on
Only two of these five
the stream, calculating the other parameters.
stream parameters
(Vapour Fraction, With the flash capabilities of UniSim Design, it is possible to
Temperature, Pressure,
Enthalpy and Entropy)
perform dew and bubble point calculations. By specifying a vapour
can be supplied. fraction of 1.0 and either the pressure or temperature of the
stream, UniSim Design will calculate the dew point temperature or
pressure. To calculate the bubble point temperature or pressure, a
vapour fraction of 0.0 and either pressure or temperature must be
entered.
Perform a P-T flash calculation on the stream GasWell 2. Set the

pressure to 7500 kPa and the temperature to 10C. What is the
vapour fraction?
_____________________________________________________
Perform a dew point calculation on the stream GasWell 2. Set the
pressure to 7500 kPa. What is the dew point temperature?
_____________________________________________________
Perform a bubble point calculation on the stream GasWell 2. Set
the pressure to 7500 kPa. What is the bubble point temperature?
_____________________________________________________
1.22
Attaching Utilities
The utilities available in UniSim Design are a set of useful tools that
interact with your process, providing additional information or
analysis of streams or operations. Once installed, the utility
becomes part of the flowsheet, automatically recalculating when
conditions change in the stream or operation to which it is
attached.
As with the majority of objects in UniSim Design, there are a
number of ways to attach utilities to streams:
To use the... Do this...

Menu Bar From the Tools menu, select Utilities.
or
Press CTRL U.
The Available Utilities view appears.
Stream Property 1. Open the Stream property view.
View 2. On the Attachments tab, click on the Utilities page.
3. Click the Create button.
The Available Utilities view appears.
Next, you will add a utility using each method of installation.
Adding a Utility from the Stream

Property View
The Envelope Utility (in the Available Utilities list) allows you to
examine relationships between selected parameters for any stream
of known composition, including streams with only one component.
Vapour-Liquid Envelopes may be plotted for the following
variables:
By default the phase Pressure - Temperature

envelope is calculated Pressure - Volume
on a dry basis (any
water is ignored). Pressure - Enthalpy
Pressure - Entropy
Temperature - Volume
Temperature - Enthalpy
Temperature - Entropy
An Envelope utility will be added to the stream GasWell 2 from
the Stream property view.
1.23
1. Open the Stream property view for GasWell 2 by double-

clicking on the stream in either the Workbook or the PFD.
2. On the Attachments tab, click the Utilities page.
Figure 15
3. Click the Create button. The Available Utilities view appears.

Figure 16
4. Select Envelope Utility. Click the Add Utility button. The

Envelope Utility view appears.
5. The Design tab shows the critical and maxima values for the
envelope.
1.24
What are the critical temperature and pressure for the stream
GasWell 2?
Tc___________________________________________________
Pc___________________________________________________
6. Switch to the Performance tab to view the phase envelope.
Figure 17
Numerical values can

be copied from UniSim
Design to Microsoft 7. Click the Table page to view envelope data in tabular format.
Excel using the copy
command, Ctrl+C, in
UniSim Design, and
then the paste Adding a Utility from the Menu
command, Ctrl+V, in
Excel. Bar
The Property Table Utility allows you to examine property trends
over a range of conditions in both tabular and graphical formats.
The utility calculates dependent variables for user specified
independent variable ranges or values.
A Property Table utility will be added to the stream Gas Well 2.
1. From the Tools menu select Utilities, or press CTRL U. The
Available Utilities view appears.
2. Select Property Table.
3. Click the Add Utility button. The Property Table view appears.
1.25
Figure 18
4. Click the Select Stream button and select stream GasWell 2.

5. Click the OK button to return to the Design tab.
6. In the Independent Variables section, select Pressure as
the first Independent Variable.
7. Change the mode to State, use the drop-down menu bar.
8. In the State Values matrix, enter values of 2500, 5000,
7500, and 9000 kPa. If you are using field units, the values
will be 350, 700, 1050 and 1400 psia.
9. Choose Temperature as the second Independent Variable.
Ensure the mode is set to Incremental.
10. Change the Lower and Upper Bounds to 0C (32F) and 100C
(212F) respectively. Leave # of Increments at the default
value of 10.
1.26
Figure 19
11. On the Design tab, click on Dep. Prop.

12. On the Dep. Prop page, click on the Add button.
13. Choose Mass Density from the list. Click OK to accept.
14. Click on the Add button again. Select the Thermal
Conductivity and click OK to accept.
15. Click the Calculate button to generate the property table.
16. Examine the property table results in either graphical or tabular
format on the Performance tab.
Figure 20
1.27
Analyzing the Results

Stream Property View
Within UniSim Design, it is possible to view the properties of the
individual phases for any stream.
1. Open the Stream property view for GasWell 3 by double-
clicking on GasWell 3 in the PFD, and view the Conditions
page.
2. Add Temperature and Pressure values of -20C (-4F) and
5000 kPa (725 psia).
3. Move the mouse arrow to the left or right side of the view until
the arrow changes to the double-headed resizing arrows.
4. Press and hold the left mouse button and drag the edge of the
view until all the phases can be seen as shown below.
Figure 21
1.28
5. Go to the Properties page. This page contains more

information about the stream properties.
Figure 22
6. Close the worksheet for GasWell 3.
1.29
Customizing the
Workbook
UniSim Design allows you to customize the Workbook at several
different levels. You can add additional pages, change the variables
Workbook icon which are displayed on the current pages, or change the format of
the values.
In this exercise, a new Workbook tab containing stream properties,
Cp/Cv, Heat of Vapourization, and Molar Enthalpy will be added.
1. Open the Workbook by clicking the Workbook icon on the tool
bar.
2. From the Workbook menu, select Setup. The Setup view

appears as shown below.
Figure 23
The Workbook menu

only appears when the
Workbook window is
active. If the PFD
window is active it is
replaced by the PFD
menu.
3. Under the Workbook Tabs group, click the Add button. The
New Object Type view appears.
1.30
Figure 24
4. Select Stream and click OK.

5. A new Workbook tab, Streams, will be listed in the Workbook
Tabs group. Ensure that this new tab is highlighted.
6. Highlight the Name cell and change the name to Other Props.
7. In the Variables group, click the Delete button until all the
default variables are removed.
8. Click the Add button to add a new variable to the tab.
9. From the Variable list, select Cp/Cv and click Add.
10. Repeat step #9 to add Mass Heat of Vapourization and
Molar Enthalpy as shown below and click Close
1.31
Figure 25
11. When complete close the Setup view to return to the

Workbook.
12. The Workbook now contains the tab Other Props which shows
the values of Cp/Cv, Mass Heat of Vapourization, and
Molar Enthalpy as shown below.
Figure 26
1.32
Printing Stream &

Workbook Datasheets
In UniSim Design you have the ability to print Datasheets for
streams, operations, and Workbooks.
Printing the Workbook Datasheet

1. Open the Workbook.
2. Right-click (object inspect) the Workbook title bar. The Print
Workbook icon
Datasheet pop-up menu appears.
1.33
Figure 27
The Workbook
Datasheet can be used
to print a report for all
the streams or a
subset. To do this:
If required, use the
Order/Hide/Reveal
Objects option on the
Workbook menu to
limit the streams
displayed.
Customize the
Workbook to contain
all the stream data
you want. 3. Select Print Datasheet. The Select Datablock view appears.
Print the Workbook
Datasheet. Figure 28
4. From the list, you can choose to print or preview any of the
available datasheets.
Printing an Individual Stream

Datasheet
To print the datasheet for an individual stream, object inspect the
stream property view title bar and follow the same procedure as for
the Workbook.
1.34
Finishing the Simulation

The final step in this section is to add the stream information
necessary for the case to be used in future modules.
Add the following temperature, pressure, and flow rate to the
streams:
Stream Temperature Pressure Flow Rate
GasWell 1 40C (105F) 4135 kPa 425 kgmole/h
(600 psia) (935 lbmole/hr)
Save your case!
1.35
Exploring the
Simulation
Exercise 1: Phase Behavior
& Hydrate Prediction
A. Use the Phase Envelope to find the following values:
Critical Point for GasWell 1.

_____________________________________________________
Cricondenbar (maximum pressure) for GasWell 1.
_____________________________________________________
Bubble Point temperature for GasWell 3 at 6000 kPa.
_____________________________________________________
Dew Point temperature for GasWell 1 at 4000 kPa.
_____________________________________________________
GasWell 1 temperature for 50% quality at 8000 kPa.
_____________________________________________________
Hydrate Formation temperature for GasWell 2 at 7500 kPa.
_____________________________________________________
1.36
B Use the Workbook to find the following values:
Bubble Point temperature for GasWell 3 at 6000 kPa.

_____________________________________________________
Dew Point temperature for GasWell 1 at 4000 kPa.
_____________________________________________________
GasWell 1 temperature for 50% quality at 8000 kPa.
_____________________________________________________
C. Use the Hydrate Formation Utility to find the hydrate formation

temperature for GasWell 1 and GasWell 2.
Pressure, kPa Hydrate

Stream
(psia) Temperature
GasWell 1 5000 (725)
GasWell 1 7500 (1090)
GasWell 2 5000 (725)
GasWell 2 7500 (1090)
1.37
Challenge
By default the phase envelope utility only performs the flash
calculations on a dry basis; it will ignore any water present in the
stream.
The composition of GasWell 3 contains some water. You have
been asked to perform a number of Dew and Bubble Point
The envelope utility can calculations on the stream at various pressures. Knowing that you
perform a calculation cannot accurately predict these points on the Phase Envelope
including the effect of (because of the water) you start to do the calculations in the
water if the UniSim
Thermo Three-Phase
Workbook. After about 30 minutes of doing flashes and writing
option is chosen from down the pressure-temperature values, your colleague comes in
combobox at the top and tells you the wonders of the Property Table and you are done
right of the in about five minutes.
Connections page.
Following your colleagues advice, set up a Property Table to
generate a Bubble Point curve and Dew Point curve from 100 to
10000 kPa.
Note: If you make any changes to the temperature and pressure
of the streams, be sure to reset them to the values given in the
Finishing the Simulation section above before saving your case.
1.38
Propane Refrigeration Loop 2.1
2. Propane
Refrigeration
Loop

4526.02.R430.01
2.2 Propane Refrigeration Loop
2.2
Workshop
Refrigeration systems are commonly found in the natural gas
processing industry and in processes related to the petroleum
refining, petrochemical, and chemical industries. Refrigeration is
used to cool gas to meet a hydrocarbon dew point specification and
to produce a marketable liquid.
In this module you will construct, run, analyze, and manipulate a
propane refrigeration loop simulation. You will convert the
completed simulation to a template, making it available to connect
to other simulations.
Learning Objectives
Once you have completed this module, you will be able to:
Add and connect operations to build a flowsheet
Use the graphical interface to manipulate flowsheets in
UniSim Design
Understand forward-backward information propagation in
UniSim Design
Convert simulation cases to templates
Prerequisites
Before beginning this module, you need to know how to:
Define a fluid package
Define streams
Navigate the Workbook interface
2.3
Process Overview
Process Overview
2.4

The first step in building any simulation is defining the fluid
package. A brief recap on how to define a fluid package and install
streams is described below. (For a complete description, see the
previous module).

Basis
1. Create a New Case and add a fluid package.
2. Specify the following property package and component:
On this page... Select...

Property Package Peng-Robinson
Components Propane
3. Click the Enter Simulation Environment button when you are

ready to start building the simulation.
Enter Simulation
Environment icon
Installing a Stream
There are several ways to create streams. (For a complete
description, see the previous module.)
Press F11. The Stream property view appears.
or
Double-click the Stream icon in the Object Palette.
Defining Necessary Streams

Add a stream with the following values:
In this cell Enter
Name 1
Vapour Fraction 0.0
Temperature 50C (120F)
Composition Propane - 100%
Add a second stream with the following properties:
2.5
In this cell Enter

Name 3
Vapour Fraction 1.0
Temperature -20C (-4F)
What is the pressure of Stream 1?

____________________________________________________
Adding Unit Operations to a

Flowsheet
As with streams, there are a variety of ways to add unit operations
in UniSim Design:
To use the Do this
Menu Bar From the Flowsheet menu, select
Add Operation
or
Press F12.
The UnitOps view appears.
Workbook Open the Workbook and go to the
UnitOps page, then click the Add
UnitOp button.
The UnitOps view appears.
Object Palette From the Flowsheet menu, select
Palette
or
Press F4. Double-click the icon of the
unit operation you want to add.
PFD/Object Using the right mouse button, drag n drop
Palette the icon from the Object Palette to the PFD.
The propane refrigeration loop consists of four operations:

Valve
Chiller
Compressor
Condenser
In this exercise, you will add each operation using a different
method of installation.
2.6
Adding a J-T Valve

The J-T Valve is modeled using the Valve operation in UniSim
Design. The inlet to the valve comes from the condenser outlet.
The condenser outlet is at its bubble point.
The valve will be added using the F12 hot key.
1. Press F12. The UnitOps view appears:
You can filter the
Available Unit
Operations list by Figure 1
selecting an appropriate
Category. In this case,
Piping Equipment
would filter the list to
include the Valve
operation.
2. Select Valve from the Available Unit Operations list.

3. Click the Add button. The Valve property view appears.
4. On the Connections page, supply the inlet and outlet
connections as shown below:
2.7
Figure 2
Drop-down lists, such

as for the Feed and
Product streams,
contain lists of available
streams which can be
connected to the
operation.
Adding a Chiller
The Chiller operation in the propane loop is modeled in UniSim
Design using a Heater operation. The outlet of the Chiller will be at
its dew point.
To add a heater:
1. Open the Workbook and click the Unit Ops tab.
2. Click the Add UnitOp button. The UnitOps view appears.
3. Select Heat Transfer Equipment from the Categories group.
4. Select Heater from the Available Unit Operations list as
shown below.
2.8
Figure 3
5. Click the Add button, or double click on Heater. The Heater

property view appears.
6. On the Connections page, enter the information as shown
below:
Figure 4
2.9
7. Go to the Parameters page.
8. Enter a Delta P value of 7.0 kPa (1 psi) and a Duty value of

1.00e+006 kJ/h (1.00e+06 Btu/hr) for the Chiller.
Figure 5
The Parameters page

will be common to most
unit operations and
contains parameters
such as Delta P, Duty,
and Efficiency.
9. Close the property view.
What is the molar flow rate of propane?

_____________________________________________________
What is the pressure drop across the J-T valve?
_____________________________________________________
What is the temperature of the valve outlet (stream 2)?
_____________________________________________________
Adding a Compressor
Compressor icon The Compressor operation is used to increase the pressure of an
inlet gas stream.
To add a compressor:
1. Press F4. The Object Palette appears.
2. Double-click the Compressor icon on the Object Palette. The
Compressor property view appears.
3. On the Connections page, enter the stream information as
shown below:
2.10
Figure 6
4. On the Parameters page, leave the Adiabatic Efficiency at

its default value of 75% as shown below:
Figure 7
Adding the Condenser

The Condenser operation completes the propane refrigeration loop.
It is placed between the Compressor and the Valve and is modeled
as a Cooler operation.
2.11
Working with a graphical representation, you can build your

flowsheet in the PFD using the mouse to install and connect
objects. This procedure describes how to install and connect the
Cooler using the Object Palette drag n drop technique.
Using Drag n Drop in the PFD

1. Click the Cooler icon on the Object Palette.
2. Move the cursor to the PFD. The cursor will change to a special
cursor, with a box and a plus (+) symbol attached to it. The
Cooler icon box indicates the size and location of the cooler icon.
3. Click again to drop the cooler onto the PFD.
There are two ways to connect the operation to a stream on the
PFD:
To connect using the Do this

Attach Mode toggle 1. Press the Attach Mode toggle button on
the PFD button bar.
2. Place the cursor over the operation. The
connection points are highlighted as
squares and rectangles. Material stream
connections are dark blue, energy stream
connections are red.
3. Move the cursor over the connection you
want to make. When over the connection
the cursor icon changes to one with a white
square, and a pop up message tells you
which connection it is.
4. Press and hold the left mouse button.
5. Move the cursor to the stream icon you
wish to connect, if a connection is allowed a
square connection point appears.
6. Move the cursor over the connection point
and release the mouse button.
CTRL key 1. Press and hold the CTRL key, notice that
the Attach Mode button appears depressed.
2. Follow the same steps as above
3. When complete, release the CTRL key.
4. From the PFD, connect stream 4 to the Condenser inlet and

connect the Condenser outlet to stream 1 using one of the
methods in the table above.
5. Add an Energy Stream. Change the name to Cond-Q.
6. Double-click on the Condenser.
7. On the Parameters page, enter a Delta P of 35 kPa (5 psi).
2.12
Figure 8
What is the compressor energy in hp?

_____________________________________________________
Hint: Clone a unit set

and set the Power to
hp units. Save your case!
2.13
Undo/Redo/Recent
Values
UniSim Design offers an undo/redo facility. It applies in the
following circumstances:
Values entered into object property values (streams/unit
operations)
PFD object moves and resizing
Object Property Views

In any object property view (e.g. a material stream or any unit
operation) UniSim Design has an unlimited undo/redo feature.
To use undo/redo use the Undo and Redo options on the Edit
menu or the short cut keys CTRL Z and CTRL Y.
Figure 9
Additionally by right clicking on any specified value a list of all

recent entered values can be entered.
2.14
Figure 10
Note that any undo/redo/recent values information is lost when

the object property view is closed. Each time an object property
view is opened fresh undo/redo/recent values information is
stored.
Note also that using the undo/redo/recent values facility has the
same effect as typing the value in the cell; any other parts of the
flowsheet that depend on the value will recalculate accordingly.
PFD object moves and

resizing
UniSim Design also has an unlimited undo/redo facility for object
moves and object resizing on the PFD. This is also accessed by the
Undo and Redo options on the Edit menu or the short cut keys
CTRL Z and CTRL Y.
Note that any undo/redo information is lost when the PFD window
is closed. Each time a PFD window is opened fresh undo/redo
information is stored.
Note also that you cannot undo object deletion.
2.15
Manipulating the PFD

The PFD is designed around using the mouse and/or keyboard.
There are a number of instances in which either the mouse or the
keyboard can be used to perform the same function. One very
important PFD function for which the keyboard cannot be used is
object inspection.
You can perform many of the possible tasks and manipulations on
the icons in the PFD by using object inspection. Place the mouse
arrow over the object you want to inspect and press the right
mouse button. An appropriate menu is produced depending upon
the object selected (Stream, Streamline, Operation, Column, PFD
Table, PFD Background, Text Annotation etc.).
A list of the objects that you can object inspect are shown in the
following table with the corresponding menus.
Object Object Inspection Menu

PFD
Text Annotations
2.16

Unit Operations
Unit Operation Tables
Workbook Tables
2.17

Streams
(Depending on where on the
stream you click, either of
these two menus will appear.
To see the long menu, right-
click on the stream icon. To see
the short menu, right-click on
the stream line).
2.18
Customize the PFD by performing the following:
1. Add the Title: Propane Refrigeration Loop by clicking the

Add Text icon on the PFD tool bar. Move the cursor to an
appropriate location on the PFD where the text should be
Add Text icon displayed and left-click the mouse button. Type the title text in
the Text Props View that appears and click OK. Modify the
title color, font and size from the options available in the Text
Annotations menu. Hint: right-click on the title to see this
menu.
2. Add a Workbook Table for the material streams in the
simulation. Hint: right click on the PFD background and use the
Add Workbook Table option.
3. Add a Table for Stream 4. Hint: right-click on Stream 4
The width of the text
box is modified by
clicking the Size Mode
Note that existing tables can be modified by double clicking on
button on the PFD them and making the desired changes.
button bar and then
clicking on the text box.
Click on either white
square that appears on
the left and right side of Save your case!
the text box and drag
to desired width.
2.19
Saving the Simulation

as a Template
A template is a complete flowsheet that has been stored to disk
with additional information included so that the flowsheet can be
added to another model as a sub-flowsheet operation.
Typically, a template is representative of a plant process module or
portion of a process module. The stored template can subsequently
be read from disk and efficiently installed as a complete sub-
flowsheet operation any number of times into any number of
different simulations.
Some of the advantages of using templates are:
Provides a mechanism by which two or more cases can be
linked together
Employs a different property package than the main case to
which it is attached
Provides a convenient method for breaking large simulations
into smaller, easily managed components
Is created once and can be installed in multiple cases
Before you convert the case to a template, it needs to be made
generic so it can be used with gas plants of various flow rates. In
this case, the Chiller Duty dictates the flow rate of propane
required.
1. Delete the Chiller Duty value.
2. From the Simulation menu, select Main Properties. The
Simulation Case view appears as shown below.
2.20
Figure 11
3. Click the Convert to Template button.

4. Click Yes to convert the simulation case to a template.
5. Answer No to the question Do you want to save the
simulation case?.
6. Go to the File menu and Save the template as
4526.02.C3Loop.utpl.
2.21

This section describes how to retrieve and print unit operation
results.
Printing Datasheets for Unit

Operations
To set up the printer, In UniSim Design you can print results through:
select Printer Setup
from the File menu, The menu bar
then select either the Object inspection of unit operations
Graphic Printer or the
Report Printer. This The Report Manager
allows you to set the
printer configuration:
printer, paper, size,
source and orientation.
Printing Using the Menu Bar
Choose one of the following options from the File menu:
Print. Lists the available Datasheets for the active unit

operation. You can highlight a Datasheet and either preview
or print it.
Figure 12
Choosing the Print

command when the PFD
is the active view will
print the PFD. There are
no datasheets available
for the PFD.
Print Window Snapshot. Prints a bitmap of the active

UniSim Design view.
2.22
Printing Using Object Inspection

Object inspect the Title Bar of the unit operation property view and
select Print Datasheet. A list of available Datablocks is displayed
for the object.
Printing Using Report Manager

1. Open the Tools menu. Select Reports. The Report Manager
view appears as shown below.
Figure 13
2. Click the Create button to add a new report. The Report

Builder view appears as shown below.
Figure 14
2.23
3. Click the Insert Datasheet button to add datasheets to your

report. You can add single or multiple unit operation Datasheets
to a report.
Figure 15
2.24
Adding Unit Operation

Data to the Workbook
Each WorkBook has a Unit Ops page by default that displays all the
unit operations and their connections in the simulation. You can
add additional pages for specific unit operations to the WorkBook.
For example, you can add a page to the WorkBook that contains
only the compressors in the simulation.
Adding a Unit Operation

Tab to the WorkBook
1. Open the Workbook. Open the Workbook menu. Select
Setup. The Setup view appears.
2. Click the Add button in the Workbook Tabs group. The New
Object Type view appears.
3. Select Rotating Equipment and expand the list. Select

Clicking on an entry
Compressor as shown.
with a + sign will
open an expanded
menu. Figure 16
4. Click OK. A new page, Compressors, containing only

compressor information is added to the Workbook.
5. Close this view.
2.25

Data to the PFD
For each unit operation, you can display a Property Table on the
PFD. The Property Table contains certain default information about
the unit operation.

Information to the PFD
1. Open the PFD.
2. Select the unit operation for which you want to add the
Remember you can Property Table.
Object Inspect an
object by selecting it 3. Object Inspect the unit operation.
and then clicking on it
4. Click Show Table.
with the right mouse
button. 5. After the table has been added, you can move it by selecting it
and dragging it with the mouse.
6. If you Object Inspect the table, you can change its properties
and appearance. You can also specify which variables the table
will show.
2.26
Advanced Modeling
One of the key design aspects of UniSim Design is how Modular
Operations are combined with a Non-Sequential solution algorithm.
Not only is information processed as you supply it, but the results
of any calculation are automatically propagated throughout the
flowsheet, both forwards and backwards. The modular structure of
the operations means that they calculate in either direction, using
information in an outlet stream to calculate inlet conditions. This
design aspect is illustrated using the Propane Refrigeration Loop.
Figure 17
Initially, the only information supplied in the case is the

temperature and vapour fraction for streams 1 and 3 and the
composition of stream 1. Since the temperature, vapour fraction,
and composition of stream 1 are known, UniSim Design will
automatically perform a flash calculation and determine the
remaining properties (pressure, intensive enthalpy, density, etc.)
which are independent of flow.
2.27
When streams 1 and 2 are attached to the valve J-T, UniSim

Design first determines what information is known in either the
input or output stream. It will then assign these values to the other
stream. In this case, since no valve pressure drop was specified,
only the composition and intensive enthalpy of stream 1 will be
passed to stream 2.
By attaching stream 2 and 3 to the heater operation, Chiller, the
composition of stream 2 is passed to stream 3 (100% Propane).
UniSim Design can now perform a flash calculation on stream 3
and determine the remaining properties which are independent of
flow, i.e. pressure, enthalpy, etc.
Using the calculated pressure of stream 3 and the specified
pressure drop across the heater, UniSim Design back calculates the
pressure of stream 2. Since pressure, composition and intensive
enthalpy of stream 2 are now known (the valve is isenthalpic),
UniSim Design can calculate the temperature of stream 2.
In addition, UniSim Design uses the specified heater duty and the
intensive enthalpy of streams 2 and 3 to calculate the flow rate,
which is then passed on to streams 1, 2 and 3.
Next, the Compressor is added to the simulation. Since all of the
inlet information is known, the compressor has only 2 degrees of
freedom remaining. Parameters such as Efficiency, Duty, or Outlet
Pressure can satisfy one degree of freedom. The second degree of
freedom comes from the Condenser.
The Condenser connects the Compressor outlet to the Valve inlet
(which is completely defined). The user supplies the Condenser
pressure drop, and UniSim Design calculates the inlet pressure,
which is also the Compressor outlet pressure (the second degree of
freedom for the Compressor).
2.28
Exploring the
Simulation
Use your saved case (not the template) for the following exercises.
Exercise 1: Design vs.

Rating Scenarios
In the plant, you are unable to accurately measure or calculate the
chiller duty. You do, however, know that the compressor is rated
for 250 hp and that it is running at 90% of maximum and 72%
efficiency.
What is the chiller duty?

_____________________________________________________
The Chiller Gas Flow meter has finally been calibrated and you can
determine the chiller duty. It has been decided to increase the
chiller duty to 1.5 MMBTU/hr.
With the compressor running at the same horsepower (225 hp),

what is the best chiller outlet temperature you can achieve (and
thus maximize cooling for the process) while still running the
compressor at a reasonable operating point?
_____________________________________________________
2.29
Exercise 2: Refrigerant
Composition
Before starting this exercise return the refrigeration loop to its
original configuration: Chiller duty specified (1.00e+006 kJ/h),
compressor adiabatic efficiency specified (75%) and power
calculated, chiller outlet temperature specified (-20C).
Your local propane dealer arrives at your plant selling a 95/5

(mole%) Propane/Ethane blend.
What effect, if any, does this new composition have on the

refrigeration loop?
_____________________________________________________
Use the base case for comparison:
Base Case: New Case:

100% Propane 5% Ethane,
95% Propane
Flow,
kgmole/h
Condenser Q,
kJ/h
Compressor Q,
hp
2.30
Challenge: Adding an
Economizer
Create a two stage refrigeration loop by adding an Economizer.
What is the net compression in hp?

_____________________________________________________
Figure 18
Add the following specifications to the refrigeration loop:
For this Item Add this specification

Stream 1 T = 50C and Vf = 0.0.
100% Propane
Chiller Pressure Drop = 7 kPa
Q = 1.0e+006 kJ/h
Stream 3 T = -20C
Vf = 1.0
Stream 4 P = 625 kPa
Mixer Equalize All Pressures
Condenser Pressure Drop = 35 kPa
Save your case!
2.31
Refrigerated Gas Plant 3.1
3. Refrigerated
Gas Plant

4526.03.R430.01
3.2 Refrigerated Gas Plant
3.2
Workshop
In this simulation, a simplified version of a refrigerated gas plant
will be modeled. The purpose is to find the LTS (Low Temperature
Separator) temperature at which the hydrocarbon dew point target
is met. The Sales Gas hydrocarbon dew point should not exceed
-15C at 6000 kPa. The incoming gas is cooled in two stagesfirst
by exchange with product Sales Gas in a gas-gas exchanger (Gas-
Gas) and then in a propane chiller (Chiller), represented here by a
Cooler operation. A Virtual Stream operation will be used to
evaluate the hydrocarbon dew point of the product stream at 6000
kPa.
Learning Objectives
Once you have completed this section, you will be able to:
Install and converge heat exchangers
Understand logical operations (Virtual Stream and Adjust)
Use the Case Study tool to perform case studies on your
simulation
Prerequisites
Before beginning this section you need to know how to:
Create a fluid package
Add streams
Add unit operations
3.3
Process Overview
Process Overview
3.4

Three tasks are required to build the simulation:
1. Defining component list and fluid package
2. Adding streams and unit operations
3. Adding logical operation (Virtual Stream and Adjust)

Basis
For this case, you will be using the Peng-Robinson EOS with the
following components:
Nitrogen i-Butane
H2S n-Butane
CO2 i-Pentane
Methane n-Pentane
Ethane n-Hexane
Propane C7+*
H2O
1. Create a New Case.
2. On the Fluid Pkgs tab import the fluid package,

4526.01.GasPlant.fpk, which you saved in Module 1 (Getting
Started).
If you want to re-create
the fluid package, refer
to the first module
(Getting Started). Adding a Feed Stream
Add a new Material stream with the following values:
3.5
In this cell Enter

Name To Refrig
Pressure 6200 kPa (900 psia)
Flow Rate 1440 kgmole/h (3175
lbmole/hr)
Component Mole Fraction
Nitrogen 0.0066
H2S 0.0003
CO2 0.0003
Methane 0.7575
Ethane 0.1709
Propane 0.0413
i-Butane 0.0068
n-Butane 0.0101
i-Pentane 0.0028
n-Pentane 0.0027
n-Hexane 0.0006
C7+* 0.0001
H2O 0
Adding a Separator
There are several ways to add unit operations. For a complete
description, see the Propane Refrigeration Loop module
(Adding Unit Operations to a Flowsheet section).
Press the F12 hot key. Select the desired unit operation
from the Available Unit Operations group.
Double-click the unit operation button in the Object Palette.
On the Connections tab, add a Separator and enter the following
information:
In this cell... Enter...
Name Inlet Gas Sep
Feed To Refrig
Vapour Outlet Inlet Sep Vap
Liquid Outlet Inlet Sep Liq
3.6
Adding a Heat Exchanger

The heat exchanger performs two-sided energy and material
balance calculations. The heat exchanger is capable of solving for
temperatures, pressures, heat flows (including heat loss and heat
Heat Exchanger icon leak), material stream flows, and UA.
1. Double-click the Heat Exchanger button on the Object Palette.
2. On the Connections page, enter the following information:
Figure 1
The Tube Side and

Shell Side streams can
come from different
Flowsheets, so for
example, you can use
Steam Tables for the
fluid package on one
side of the exchanger
and Peng-Robinson on
the other side.
3. Switch to the Parameters page. Complete the page as shown

in the following figure. Set the Heat Exchanger Model to
Exchanger Design (Weighted). The pressure drops for the
Tube and Shell sides will be 35 kPa (5 psi) and 5 kPa
(1 psi), respectively.
3.7
Figure 2
The heat exchanger models are defined as follows:

Weighted. The heating curves are broken into intervals,
which then exchange energy individually. An LMTD and UA
are calculated for each interval in the heat curve and
summed to calculate the overall exchanger UA. The
Weighted method is available only for Counter-Current
exchangers.
End Point. A single LMTD and UA are calculated from the
inlet and outlet conditions. For simple problems where there
is no phase change and Cp is relatively constant, this option
may be sufficient.
4. Go to the Specs page.
To solve the heat exchanger, unknown parameters (flows,
temperatures) are manipulated by the solver. Each constraint
(specification) will reduce the degrees of freedom by one. The
number of constraints (specifications) must equal the number of
unknown variables. When this is the case, the degrees of freedom
will be equal to zero, and a solution will be calculated.
3.8
Two specifications are needed for this exchanger:
Heat Balance = 0. This is a Duty Error specification and is

needed to ensure that the heat equation balances. This is a
default specification that is always added by UniSim Design
so you do not need to supply it.
Min Approach = 5C. This is the minimum temperature
difference between the hot and cold stream.
You can have multiple 5. To add a specification, click the Add button, the ExchSpec
Estimate specifications. view appears.
The Heat Exchanger will
only use the Active
Figure 3
specifications for
convergence.
6. Provide the following information:

Name Temp Approach
Type Min Approach
Pass Overall
Spec Value 5C (9F)
When you change the type of specification, the view will change
accordingly. Once all the information has been provided, the view
will be as shown below:
Figure 4
3.9
7. Activate the new specification by checking the Active checkbox:
Figure 5
What is the flow rate of Gas to Chiller?

_____________________________________________________
3.10
Finishing the Simulation

Add the two remaining physical unit operations to complete the
simulation.
1. Add a Cooler and provide the following information:
In this cell Enter

Connections
Name Chiller
Inlet Stream Gas to Chiller
Outlet Stream Gas to LTS
Energy Stream Chiller Q
Parameters
Delta P 35 kPa (5 psi)
2. Add a Separator and provide the following information on the

Connections tab:
In this cell Enter

Name LTS
Inlet Stream Gas to LTS
Vapour Outlet LTS Vap
Liquid Outlet LTS Liq
What piece of information is required for the LTS separator to

solve?
_____________________________________________________
3.11
In the next section the LTS feed temperature will be varied using
an Adjust operation to find a temperature at which the dew point
constraint is met. For now, specify the temperature of stream Gas
to LTS to be -20C (-4F).
What is the pressure of Sales Gas?

_____________________________________________________
What is the temperature of Sales Gas?
_____________________________________________________
3.12
Adding a Virtual Stream

The Virtual Stream operation provides a general purpose facility to
create a live copy of the data from one stream (the Reference
Virtual Stream icon
stream) to another (the Target stream). The Reference and Target
streams must be specified on the Connections tab. The Virtual
Stream operation may also be used in other cases, for example, to
perform flash calculations.
Figure 6
To make a duplicate of a stream, four reference variables must be

selected in the Transfer Information section of the Parameters
tab as depicted in Figure 7 below. Composition must be selected,
flow (molar or mass) and two of either: vapour fraction,
temperature, pressure and enthalpy. Selecting pressure and
The Virtual Stream is enthalpy as the last two variables will define the stream uniquely.
classified with the
logical operations on Note backward translation from the Target Stream to the
the Object Palette. Reference Stream is also possible if the corresponding property of
The Virtual Stream the reference stream is deleted and the property of the target
operation shows green
stream is specified instead.
connections because it
does not imply a
material balance.
3.13
Figure 7
In order to use the Virtual Stream operation to perform flash

calculations, composition and flow (molar or mass) must be
selected in the Transfer Information area of the Virtual Stream
Parameters tab. The user will specify the flash variables, vapour
fraction, pressure and/or temperature, depending on whether dew
or bubble point calculations are the desired target.
1. Double-click on the Virtual Stream icon on the Object Palette.

2. Add the following information on the Connections tab:

Reference Stream Sales Gas
The Virtual Stream
operation translates Target Stream HC Dew Point
stream data using a
multiplier and offset per 3. Go to the Parameters tab.
the following linear
formula: 4. Select composition and flow (molar or mass).
Y = M*X + B 5. Specify a Pressure of 6000 kPa (870 psia) for the stream HC
M=Multiplier, B=Offset Dew Point, and set the Vapour Fraction to calculate the dew
Y is the Target stream point temperature. This can be done on the Parameters tab
data, and X is the
of the Virtual Stream (Target Value), or on the Worksheet tab
Reference stream data.
of the HC Dew Point stream itself. Observe that entering the
values in one will populate the other.
3.14
Figure 8
What is the dew point temperature?

_____________________________________________________
The required dew point is -15C, is the current dew point higher or
lower?
_____________________________________________________
Assuming pressure is fixed, what other parameter affects the dew
point?
_____________________________________________________
How can we change the dew point in the simulation?
_____________________________________________________
3.15
Adding the Adjust

The Adjust operation is a Logical Operation; a mathematical
operation rather than a physical operation. It will vary the value of
Adjust icon
one stream variable (the independent variable) to meet a required
value or specification (the dependant variable) in another stream
or operation.
1. Double-click on the Adjust icon on the Object Palette, the
Adjust property view appears.
Figure 9
The Adjusted Variable

must always be a user-
specified value.
2. Click the Select Var... button in the Adjusted Variable group.

The Variable Navigator view appears.
3. From the Object list, select Gas to LTS. From the Variable list
which is now visible, select Temperature.
3.16
Figure 10
4. Click the OK button to accept the variable and return to the

Adjust property view.
Always work left to
right in the Variable 5. Click the Select Var... button in the Target Variable group.
Navigator. Dont forget
6. Select the object HC Dew point, and then select
you can use the Object
Filter when the Object Temperature as the target variable.
list is long. 7. Click the OK button to accept the variable and return to the
Adjust property view.
8. Enter a value of -15C (5F) in the Specified Target Value box.
9. The completed Connections tab is shown below.
Figure 11
3.17
10. Switch to the Parameters tab, and enter Minimum and

Maximum values of -20C (-4F) and 0C (32F) respectively:
Figure 12
When adjusting certain

variables, it is often a
good idea to provide a
minimum or maximum
which corresponds to a
physical boundary, such
as zero for pressure or
flow.
Note the Tolerance and Step Size values. When considering step
sizes, use larger rather than smaller sizes. The Secant method
works best once the solution has been bracketed and by using a
larger step size you are more likely to bracket the solution quickly.
11. To view the progress of the Adjust, go to the Monitor tab.
3.18
Figure 13
What is the Chiller outlet temperature required to achieve the dew

point specification?
_____________________________________________________
Save your case!
3.19
Choosing the Adjust Method

In Sequential (i.e. Non-simultaneous) mode the Adjust has a
choice of three methods:
Secant (default)
Broyden
The Modified Secant Modified Secant
method was introduced
in UniSim Design R380. In general the Secant is slower but more reliable than the Broyden
method. The Modified Secant method includes several
enhancements over the original Secant method:
More efficient control of internal variable bounds and step
size.
Better able to find a bracket for the solution.
Reverts to Bi-Section search if unable to find a solution
otherwise.
When the calculation is stuck at one variable bound, it will
switch to the other bound and continue calculations.
In combination this method allows the Adjust to better cope with
the situation where the target variable is invariant over a portion of
the adjusted variable range. The Modified Secant method is a good
general purpose choice.
3.20
Advanced Modeling
Linking the Propane Loop to
the Gas Plant
Once you have completed the Refrigerated Gas Plant example, you
can link it to the Propane Loop template.
Sub-Flowsheet icon
The Chiller duty, Chiller Q, in the Gas Plant will be linked to the
Chiller duty, Chill-Q, in the Propane Refrigeration Loop template.
1. Using the Refrigerated Gas Plant simulation constructed above
double-click on the Sub-Flowsheet icon on the Object Palette.
2. Click the Read an Existing Template button.
3. Navigate to the template file saved in Module 2,
4526.02.C3Loop.utpl, and click Open.
4. In the Inlet Connections to Sub-Flowsheet group, connect

the External Stream, Chiller Q to the Internal Stream Chill Q.
Figure 14
If at this point a
consistency error occurs
consider these
questions:
What variable is being
transferred from the
main flowsheet stream
to the sub-flowsheet?
Does the sub-flowsheet
stream already have a
value for this variable?
Why?
When the problem is
fixed what needs to be
done to get UniSim
Design to start solving
again?
3.21
Once the connection is complete, both streams (internal and

external) will have the same name (that of the external stream).
What is the flow rate of propane in the Refrigeration Loop?

_____________________________________________________
3.22
Exploring the
Simulation
Exercise 1: Modifying the
Exchanger
The available UA for the Gas-Gas Exchanger is only 2e+005
kJ/C.h. Make the necessary modifications to your exchanger
design to achieve this UA.
How does this affect the LMTD and Temperature Approach?

_____________________________________________________
Challenge
In building the Refrigerated Gas Plant and the Propane
Refrigeration Loop you decided to shortcut things and add a single-
sided Cooler operation instead of the shell and tube exchanger that
will actually be in the plant. This shortcut works for preliminary
work, but now you need to replace the cooler with a shell and tube
exchanger.
Remember, UniSim Design allows you to attach streams from
another flowsheet to either side of the heat exchanger. Using this
feature, you should be able to solve this problem with only an
exchanger in the Refrigerated Gas Plant (no exchanger in the
Propane Refrigeration Loop).
3.23
Using the Case Study

Open the starter case: 4526.03.CaseStudyStarter.usc. This case
is the solution to the Challenge problem in Module 2. The Case
Study tool allows you to monitor the steady state response of key
process variables to changes in your process. You select
independent variables to change and dependent variables to
monitor. UniSim Design varies the independent variables one at a
time, and with each change, the dependent variables are
calculated.
The economizer in the propane refrigeration loop results in a
saving of energy over the single compression loop. The outlet
Any unit operation can
pressure from the first stage compressor (Stream 4) has a
be temporarily removed
from the calculations by significant effect on the total compression power required. We will
selecting the Ignore use the Case Study to see the effect of changing the first stage
checkbox. compressor outlet pressure on the total power required by the
refrigeration loop.
Note: If your case contains any Adjust operations, they must be
turned off so that they do not conflict with the Case Study.
1. From the Tools menu select Databook (or press CTRL D), to
open the Databook.
Figure 15
Both the independent

and the dependent
variables are added to
the Databook from the
Variables tab.
2. On the Variables tab, click the Insert button to open the

Variable Navigator.
3. Select the Pressure of stream 4 as the first variable.
3.24
4. Click the Add button to add the variable.

5. Select spreadsheet Compressor HP, cell B4 and click Add.
Click Close to close the Variable Navigator Window.
6. In the Databook, switch to the Case Studies tab.
7. Click the Add button to add a new Case Study.
Only user-specified 8. Select Stream 4 Pressure as the Independent Variable and
variables can be
selected as Compressor HP cell B4 as the Dependent Variable.
Independent Variables.
Figure 16
9. Click the View button to set up the Case Study.

10. Enter values for Low Bound, High Bound, and Step Size of
300 kPa (45 psia), 1600 kPa (235 psia) and 50 kPa (5 psi)
respectively.
Figure 17
11. Click the Start button to begin calculations.
3.25
What First Stage compressor outlet pressure (Stream 4) will result

in the minimum power usage in the Refrigeration Loop?
_____________________________________________________
3.26
NGL Fractionation Train 4.1
4. NGL
Fractionation
Train

4526.04.R430.01
4.2 NGL Fractionation Train
4.2
Workshop
Recovery of natural-gas liquids (NGL) from natural gas is quite
common in natural gas processing. Recovery is usually done to:
Produce transportable gas (free from heavier hydrocarbons
which may condense in the pipeline)
Meet a sales gas specification
Maximize liquid recovery (when liquid products are more
valuable than gas)
UniSim Design can model a wide range of different column
configurations. In this simulation, an NGL Plant will be constructed,
consisting of three columns:
De-Methanizer (operated and modeled as a Reboiled
Absorber column)
De-Ethanizer (Distillation column)
De-Propanizer (Distillation column)
Learning Objectives
Add columns using the Input Experts
Add extra specifications to columns
Prerequisites
Before beginning this module, you need to know how to:
Create a fluid package
Add streams
Add unit operations
Navigate the Workbook interface
4.3
Process Overview Process Overview
4.4
Column Overviews
DC1: De-Methanizer
Figure 1
4.5
DC2: De-Ethanizer
Figure 2
4.6
DC3: De-Propanizer
Figure 3
4.7

Basis
1. Start a new case.
2. Select the Peng-Robinson EOS.
3. Add the components:
Nitrogen n-Butane
CO2 i-Pentane
Methane n-Pentane
Ethane n-Hexane
Propane n-Heptane
i-Butane n-Octane
4. Enter the Simulation Environment.
Enter Simulation
Environment icon Adding the Feed Streams
1. Add a Material Stream with the following data:

Name Feed1
Flow rate 1620 kgmole/h
(3575 lbmole/hr)
Nitrogen 0.0025
CO2 0.0048
Methane 0.7041
Ethane 0.1921
Propane 0.0706
i-Butane 0.0112
n-Butane 0.0085
4.8

i-Pentane 0.0036
n-Pentane 0.0020
n-Hexane 0.0003
n-Heptane 0.0002
n-Octane 0.0001
2. Add a Material Stream with the following data:

Name Feed2
Flow rate 215 kgmole/h (475 lbmole/hr)
Nitrogen 0.0057
CO2 0.0029
Methane 0.7227
Ethane 0.1176
Propane 0.0750
i-Butane 0.0204
n-Butane 0.0197
i-Pentane 0.0147
n-Pentane 0.0102
n-Hexane 0.0037
n-Heptane 0.0047
n-Octane 0.0027
4.9
Adding the Unit Operations

De-Methanizer
The De-Methanizer is modeled as a reboiled absorber operation,
with two feed streams and an energy stream feed, which
Reboiled Absorber represents a side heater on the column.
Column icon
1. Add an Energy stream with the following values:

Name Ex Duty
Energy Flow 2.1e+006 kJ/h (2.0e+06Btu/hr)
2. Double-click on the Reboiled Absorber icon on the Object

Palette. The first Input Expert view appears.
3. Complete the view as shown below:
Figure 4
The Input Expert

provides the new user
with step by step
instruction for defining
a column.
4.10
4. Click the Next button to proceed to the next page.
5. Supply the following information on the Pressure Profile page.

If you are using field units, the values will be 330 psia and
335 psia, for the Top Stage Pressure and Reboiler Pressure,
The Next button is only respectively.
available when all of the
necessary information
has been supplied. Figure 5
6. Click the Next button to proceed to the next page.

7. Enter the temperature estimates shown below. In field units,
the top stage temperature estimate will be -88C, and the
Temperature estimates
reboiler temperature estimate will be 27C
are not required for the
column to solve but
they will aid in
convergence.
4.11
Figure 6
8. Click the Next button to continue.
9. For this case, no information is supplied for the Boil-up Ratio

on the last page of the Input Expert, so click the Done button.
Figure 7
The basic Reboiled

Absorber has a single
DOF.
When you click the Done button, UniSim Design opens the Column
property view. Access the Monitor page on the Design tab.
4.12
Figure 8
Before you converge the column, make sure that the specifications
are as shown above. You will have to enter the value for the Ovhd
Prod Rate specification. The specified value is 1338 kgmole/h
(2950 lbmole/hr).
10. Click the Run button to run the column.
What is the mole fraction of Methane in DC1 Ovhd?

_____________________________________________________
Note: Although the column is converged, it is not always practical

to have flow rate specifications. These specifications can result in
columns which cannot be converged or that produce product
streams with undesirable properties if the column feed conditions
change.
An alternative approach is to specify either component fractions or
component recoveries for the column product streams.
11. Go to the Specs page on the Design tab of the Column
property view.
4.13
Figure 9
12. Click the Add button in the Column Specifications group to

create a new specification.
13. Select Column Component Fraction from the list that
appears.
Figure 10
14. Click the Add Spec(s) button.

15. Complete the spec as shown in the following figure.
4.14
Figure 11
16. When you have finished, close the view.

The Monitor page of the column property view shows 0 Degrees of
Freedom even though you have just added another specification.
This is due to the fact that the specification was added as an
estimate, not as an active specification.
17. Go to the Monitor page. De-activate Ovhd Prod Rate as an
active specification and activate the Comp Fraction
specification (C1 in Overhead) which you created.
What is the flow rate of the overhead product, DC1 Ovhd?

____________________________________________________
Once the column has converged, you can view the results on the
Performance tab.
4.15
Figure 12
Adding a Pump
The pump is used to move the De-Methanizer bottom product to
the De-Ethanizer.
Pump icon
Install a pump and enter the following information:

Connections
Inlet DC1 Btm
Outlet DC2 Feed
Energy P-100-HP
Worksheet
DC2 Feed Pressure 2790 kPa (405 psia)
De-Ethanizer
The De-Ethanizer column is modeled as a distillation column, with
16 separation stages; 14 stages in the tray section, plus the
Distillation Column icon reboiler and condenser. It operates at 2760 kPa (400 psia)
pressure. The objective is to produce bottom product with a ratio of
ethane to propane of 0.01.
1. Double-click on the Distillation Column button on the Object
Palette and enter the following information:
4.16

Connections
Name DC2
No. of Stages 14
Inlet Stream/Stage DC2 Feed/6
Condenser Type Partial
Overhead Vapour Product DC2 Ovhd
Overhead Liquid Product DC2 Dist
Bottoms Liquid Outlet DC2 Btm
Reboiler Duty Energy DC2 Reb Q
Condenser Duty Energy DC2 Cond Q
Pressures
Condenser 2725 kPa (395 psia)
Condenser Delta P 35 kPa (5 psi)
Reboiler 2792 kPa (405 psia)
Temperature Estimates
Condenser -4C (25F)
Reboiler 95C (200F)
Specifications
Overhead Vapour Rate 320 kgmole/h (700 lbmole/hr)
Distillate Rate 0 kgmole/h
Reflux Ratio 2.5 (Molar)
2. Click the Run button to run the column.
What is the flow rate of Ethane and Propane in DC2 Btm?

Ethane____________________, Propane____________________
What is the ratio of Ethane/Propane?
_____________________________________________________
3. On the Specs page, click the Add button to create a new

specification.
4. Select Column Component Ratio as the Column
Specification Type and provide the following information:

Name C2/C3
Stage Reboiler
4.17

Flow Basis Mole Fraction
Phase Liquid
Spec Value 0.01
Numerator Ethane
Denominator Propane
5. On the Monitor tab, de-activate the Ovhd Vap Rate

specification and activate the C2/C3 specification which you
created.
What is the flow rate of DC2 Ovhd?

____________________________________________________
Adding a Valve
A valve is required to reduce the pressure of the stream DC2 Btm
before it enters the final column, the De-Propanizer.
Valve icon
Add a Valve operation and provide the following information:

Connections
Inlet DC2 Btm
Outlet DC3 Feed
Worksheet
DC3 Feed Pressure 1690 kPa (245 psia)
4.18
De-Propanizer
The De-Propanizer column is represented by a distillation column
consisting of 25 separation stages, 24 stages in the tray section
Distillation Column icon plus the reboiler (note: a total condenser does not count as a
separation stage). It operates at 1620 kPa (235 psia). There are
two process objectives for this column; to produce an overhead
product that contains no more than 1.50 mole percent of i-C4 and
n-C4, and that the concentration of propane in the bottom product
should be less than 2.0 mole percent.
1. Add a distillation column and provide the following information:

Connections
Name DC3
No. of Stages 24
Inlet Streams/Stage DC3 Feed/11
Condenser Type Total
Ovhd Liquid Outlet DC3 Dist
Bottom Liquid Outlet DC3 Btm
Reboiler Duty Energy DC3 Reb Q
Condenser Duty Energy DC3 Cond Q
Pressures
Condenser Delta P 35 kPa (5 psi)
Reboiler 1655 kPa (240 psia)
Temperature Estimates
Condenser 38C (100F)
Reboiler 120C (250F)
Specifications
Distillate Rate 110 kgmole/h (240 lbmole/hr)
Reflux Ratio 1.0 (Molar)
2. Run the column.
What is the mole fraction of Propane in the product streams?

Overhead_________________ Bottoms _____________________
3. Create two new Component Fraction specifications for the

column.
4.19

i-Butane and n-Butane in Distillate
Name iC4 and nC4
Stage Condenser
Phase Liquid
Spec Value 0.015
Components i-Butane and n-Butane
Propane in Reboiler Liquid
Name C3
Stage Reboiler
Phase Liquid
Spec Value 0.02
Component Propane
4. De-activate the Distillate Rate and Reflux Ratio

specifications.
5. Activate the i-Butane, n-Butane, and Propane specifications
that you created.
Save your case!
4.20
Advanced Modeling
The column is a special type of sub-flowsheet in UniSim Design.
Sub-flowsheets contain equipment and streams, and exchange
information with the parent flowsheet through the connected
streams. From the main environment, the column appears as a
single, multi-feed, multi-product operation. In many cases, you can
treat the column in exactly that manner.
The column sub-flowsheet provides a number of advantages:
Isolation of the column solver. The Column Environment
allows you to make changes and focus on the column
without the re-calculation of the entire flowsheet.
Optional use of different fluid packages. UniSim Design
allows you to specify a unique (different from the main
environment) fluid package for the column sub-flowsheet.
This is useful when a different fluid package is better suited
to the column (e.g. a Gas Plant using PR may contain an
Amine Contactor that needs to use the Amines Property
Package), or the column does not use all of the components
used in the main flowsheet and so by decreasing the
number of components in the column you may speed up
column convergence.
Construction of custom templates. In addition to the default
column configurations which are available as templates, you
may define column setups with varying degrees of
complexity. Complex custom columns and multiple columns
may be simulated within a single sub-flowsheet using
various combinations of sub-flowsheet equipment. Custom
The presence of the column examples include, replacement of the standard
green Up Arrow icon
in the toolbar and the
condenser with a heat exchanger, or the standard kettle
Environment Name i.e. reboiler with a thermosyphon reboiler.
(COL1) indicates that Ability to solve multiple towers simultaneously. The column
you are in the column.
sub-flowsheet uses a simultaneous solver whereby all
operations within the sub-flowsheet are solved
simultaneously. The simultaneous solver permits the user to
install multiple interconnected columns within the sub-
flowsheet without the need for recycle blocks.
4.21
You can enter the column sub-flowsheet by clicking the Column

Environment button in the column property view. Once inside the
column environment, you can return to the parent environment by
either:
Clicking the Enter Parent Simulation Environment icon

in the toolbar.
Enter Parent Simulation
Environment icon or
Clicking the Parent Environment button in the Column
Runner view, as shown below:
Figure 13
If the Column Runner view is not open, click on the Column

Column Runner icon Runner icon in the toolbar.
4.22
Exploring the
Simulation
Challenge 1
After simulating your De-Methanizer, you have to use UniSim
Design to determine the UA for the De-Methanizer Reboiler.
Instead of changing the configuration of the column, you can
create an internal stream in the Column Flowsheet (on the
Flowsheet tab). This stream represents the liquid that flows from
the bottom tray to the reboiler, which can then be added to a heat
exchanger in the Main Flowsheet. Use steam to exchange heat with
the process stream.
Assume that you have 1000 kgmole/h of saturated 100 psi steam
available for the shell side and there is a 5 psi pressure drop on the
steam side. Your overhead Methane spec of 0.96 (mole) must still
be met.
Remember, you will need to add water to your component list.
4.23
Challenge 2
For the valve VLV-100 between the De-Ethanizer and the De-
Propanizer, the manufacturer provides you with some data about
the geometry/size of this valve. Your colleague analyzes this
information and comes back with the following data for the valve.
Valve VLV-100
Valve Manufacturer Universal Gas Sizing
Conductance (Cv) 16 USGPM
Characteristic Linear
The plant operator adds that when the column operates at steady
state, valve VLV-100 is opened 30% and the pressure of the inlet
stream DC3 Feed should stay within the range of 1600 kPa and
1800 kPa.
Use the information received from your colleague and the P-F
Relation specification instead of the Delta P specification for valve
VLV-100. Check that the valve stays within the pressure range for
stream DC3 Feed when operating at steady state.
4.24
Oil Characterization 5.1
5. Oil
Characterization

4526.05.R430.01
5.2 Oil Characterization
5.2
Workshop
The oil characterization function in UniSim Design converts
laboratory analyses of condensates, crude oils, petroleum cuts and
coal-tar liquids into a series of discrete hypothetical components.
These petroleum hypocomponents provide the basis for the
property package to predict the remaining thermodynamic and
transport properties necessary for fluid modeling.
UniSim Design produces a complete set of physical and critical
properties for the petroleum hypocomponents with a minimal
amount of information. However, the more information you supply
about the fluid, the more accurate these properties will be, and the
better UniSim Design will predict the fluid's actual behavior.
In this example, the Oil Characterization option in UniSim Design is
used to model a reservoir fluid. The fluid is a combined gas and oil
stream.
Learning Objectives
Understand oil characterization
Enter Oil data into UniSim Design and characterize an oil
Prerequisites
Before beginning this module you need to understand the basics of
the Fluid Package (refer to the Getting Started module).
5.3
Oil Characterization
The Oil Characterization environment provides a location where the
characteristics of a petroleum fluid (condensates, crude oils,
petroleum cuts, and coal-tar liquids) can be represented by using
discrete hypothetical components. Physical, critical, transport, and
thermodynamic properties are predicted for each hypocomponent
using selected correlations. The fully defined hypocomponent can
then be installed in a stream and used in any flowsheet.
The petroleum characterization in UniSim Design accepts different
types of information about the oil. The more information you can
supply about your sample, the more accurate the representation.
The minimum amount of information that UniSim Design requires
to characterize an oil is:
a laboratory distillation curve
or
two of the following bulk properties:
Molecular Weight, Density, or Watson K Factor
Figure 1 illustrates the make-up of a typical oil:
Figure 1
An Oil or Blend is comprised of any number of Assays. Each

individual assay contains specific information with respect to the
Bulk Properties, Boiling Point Curve and Property Curves.
5.4
There are three general steps to follow when creating an oil in

UniSim Design:
1. Characterize the assay
2. Generate hypocomponents
3. Install the oil in the flowsheet
Characterize the Assay

UniSim Design defines the hypocomponents by using assay data
which you provide. The assay contains all of the petroleum
laboratory data, boiling point curves, light ends, property curves
and bulk properties. UniSim Design uses the supplied assay data to
generate internal TBP, molecular weight and density and viscosity
curves (referred to as Working Curves). Just as with fluid
packages, assays can be imported and exported to be used in
different cases.
The procedure UniSim Design uses to convert assay data into a
series of petroleum hypocomponents involves four major internal
characterization steps:
Based on input data, UniSim Design calculates a detailed set
of full range Working Curves that include the True Boiling
Point (TBP) Temperature, Molecular Weight, Density and
Viscosity behavior.
Next, by using either a default or user-supplied set of
cutpoint temperatures, the corresponding fraction for each
hypocomponent is determined from the TBP working curve.
The Normal Boiling Point (NBP), Molecular Weight, Density
and Viscosity of each hypocomponent are graphically
determined from the working curves.
For each hypocomponent, UniSim Design calculates the
remaining critical and physical properties from designated
correlations, based upon the component's NBP, Molecular
Weight and Density.
Knowledge of the four phases of the characterization process
provides a better understanding of how the input data
influences the final outcome of the characterization.
5.5
Assay Types
Accurate volatility characteristics are vital when representing a
petroleum fluid in your process simulation. For all Distillation
Curves, you are required to enter at least 5 data points. UniSim
Design accepts the following standard laboratory analytical assay
procedures:
True Boiling Point (TBP). Performed using a multi-stage

batch fractionation apparatus operated at relatively high
reflux ratios (15-100 theoretical stages with reflux ratios of
5:1 or greater). TBP distillations conducted at atmospheric
or vacuum conditions are accepted by the characterization.
ASTM D86. Distillation employing batch fractionation but
conducted using non-refluxed Engler flasks. Generally used
for light to medium petroleum fluids. UniSim Design can
For all the distillation correct for barometric pressure or cracking effects. You
curves, you are
must provide the data on a liquid volume basis.
required to enter at
least five data points. ASTM D1160. Distillation employing batch fractionation but
conducted using non-refluxed Engler flasks. Generally used
for heavier petroleum fluids. Curves can be given at
atmospheric pressure or corrected for vacuum conditions.
You must provide the data on a liquid volume basis.
ASTM D86_D1160. This is a combination of the
D86/D1160 distillation data types. You can correct for
thermal cracking and enable vacuum distillation for sub-
atmospheric conditions. You must provide data on a liquid
volume basis.
ASTM D2887. Simulated distillation analysis from
chromatographic data. Reported only on a weight percent
basis at atmospheric conditions.
Equilibrium Flash Vapourization (EFV). Involves a
series of experiments at constant atmospheric pressure,
where the total vapour is in equilibrium with the
unvapourized liquid. You must provide data on a liquid
volume basis.
Chromatographic Analysis. A gas chromatograph analysis
During calculations,
of a small sample of completely vapourized oil, analyzed for
UniSim Design
automatically converts paraffin, aromatic, and naphthenic hydrocarbon groups
all curves to TBP basis. ranging from C6 to C30. Chromatographic analyses may be
entered on a mole, mass or liquid volume basis.
The characterization procedure performs its calculations based on
an internally calculated TBP curve. If an ASTM or EFV distillation
curve is supplied, it is converted to a TBP. If no distillation data is
supplied, an average TBP distillation curve is generated, based on
the overall MW, density, and Watson (UOP) K factor of the fluid.
5.6
Light Ends
Light Ends are defined as pure components with low boiling points.
Most notably components in the boiling range of C2 to n-C5.
UniSim Design uses your Light Ends data to either define, or
replace the low boiling portion of your TBP, ASTM D86, or ASTM
D1160 curve with discrete pure components.
UniSim Design provides three options to account for Light Ends:

Ignore. UniSim Design characterizes the Light Ends portion
of your sample as hypocomponents. This is the least
accurate method and as such, is not recommended.
Auto Calculate. Select this when you do not have a
By pressing the Light separate Light Ends analysis but you want the low boiling
Ends Handling & Bulk
Fitting Options button portion of your assay represented by pure components.
on the Input Data tab UniSim Design will only use the pure components you have
of the Assay, UniSim selected in the fluid package.
Design allows the user
to specify whether the Input Composition. Select this when you have a separate
entered distillation Light Ends assay and your petroleum assay was prepared
curve includes light with the Light Ends in the sample. UniSim Design provides a
ends or not.
form listing the pure components you selected in the fluid
package. This is the most accurate representation method.
Bulk Properties
Bulk Properties for the sample may also be supplied. The bulk
properties are optional if a distillation curve or chromatograph have
been supplied.
Molecular Weight. This is the Molecular Weight of the bulk
sample. It must be greater than 16.
Mass Density. The mass density must be between 250 and
2000 kg/m3. The units for density can be mass density, API
or specific gravity, chosen from the drop-down unit list.
Watson (UOP) K Factor. This must be between 8 and 15.
The Watson K Factor is an approximate index of
paraffinicity, K = (Mean Avg BP)1/3/ (sp gr 60F/60F).
Bulk Viscosities. Given at two reference temperatures,
typically 37.78C and 98.89C (100F and 210F).
Physical Property Curves

UniSim Design accepts different types of physical property curves:
Molecular Weight curve
5.7
Density curve
Viscosity curve
Physical property analyses are normally reported from the
laboratory using one of the following two conventions:
Dependent Assay Basis. A common set of assay fractions
is used for both the distillation curve and the physical
property curve.
Independent Assay Basis. A common set of assay
fractions is not used for both the distillation curve and the
physical property curve.
If property curve data is not supplied, UniSim Design generates
internal curves, calculated/estimated by using correlations
designed to model a wide variety of oils.
Property Correlations
UniSim Design allows you to choose from a wide variety of
correlations (estimation methods) to determine the properties of
the generated hypocomponents. The Correlation tab of the Oil
Characterization Manager allows you to manage the correlations in
your case. From this tab you can easily add new correlation sets
and modify existing correlation sets.
The Default Set of correlations is as follows:
The Default Set of
correlations cannot be Property... Default Correlation...
modified. To specify
different correlations or MW (Molecular Weight) Twu
temperature ranges a SG (Specific Gravity) Constant Watson K
new correlation set
must be created. Tc (Critical Temperature) Lee-Kesler
Pc (Critical Pressure) Lee-Kesler
Acentric Factor Lee-Kesler
Ideal Enthalpy Lee-Kesler
In the correlation set window, correlation changes are specified by

using the drop-down list in any, or all of the property columns:
MW, SG, Tc, Pc, Acc. Factor, and Ideal H.
5.8
The Low and High End Temperature cells are the range the
selected correlation set is applied to. A property correlation can be
changed over an entire range, or a particular correlation can be
made valid for a particular boiling point range only by splitting the
range. If a range is split, then more than one temperature range
will be displayed. As many temperature splits as desired may be
added to a correlation set. Temperature splits can be modified any
time by simply clicking in the appropriate cell and specifying a new
value. Temperature splits may also be removed by merging
temperature ranges.
Changes to the assay Changes to the Molecular Weight or Specific Gravity correlations
correlations have no are applied to the assay curve, while the Critical Temperature,
effect when a property Critical Pressure, Acentric Factor and Heat Capacity correlations are
curve is supplied (i.e.
applied to the hypocomponent properties of the blend.
MW curve). Changes
only apply when Any changes to the correlations for an input assay will result in first
UniSim Design is
estimating the
the assay being recalculated, followed by any blend that uses that
properties. assay. For an existing oil, it will be automatically recalculated/re-
cut using the new correlations, and the new components will be
installed in the flowsheet.
Hypocomponent
Generation/Oil Blending
Cutting and Blending is The Cut/Blend characterization in UniSim Design splits the internal
always a balance of working curves for one or more assays into hypocomponents. The
computation speed Cut/Blend tab of the Oil Characterization view provides two
(less components)
functions, cutting the oil into hypocomponents and blending two or
against precision (more
components). more Assays into one set of hypocomponents.
5.9
Cut Ranges
You have three choices for the Cut Option Selection:
Auto Cut - UniSim Design cuts the assay based on internal
values.
Range... Cuts...
o o
37.78 425 C (100 - 800 F) 28 (4 per 37.78oC or 100oF)
425 650oC (800 - 1200oF) 8 (2 per 37.78oC or 100oF)
When different crudes
650 870oC (1200 - 1600oF) 4 (1 per 37.78oC or 100oF)
are from very different
sources, it is a good
idea to blend them User Points - You specify the number of hypocomponents
separately (create two required. UniSim Design proportions the cuts according to
different blends), and
mix them in the an internal weighting scheme.
Simulation Environment
instead of from within Range... Cuts...
the Oil Manager. o o
IBP - 425 C (IBP - 800 F) 4 per 37.78oC or 100oF
The reason is that the
Oil Manager in 425 - 650oC (800 - 1200oF) 2 per 37.78oC or 100oF
UniSim Design must
650 - FBP (1200 - FBP) 1 per 37.78oC or 100oF
generate a set of
common hypo
components that User Ranges - You specify the boiling ranges and the
predict the properties of number of cuts per range.
both source oils, which
is not necessarily a
Installing the Oil in the

reasonable expectation
for very different
crudes.
Flowsheet
The final step of the characterization is to transfer the
hypocomponent information into the flowsheet.
5.10

Before you start the characterization process, you must:
Select a property package
Add any non-oil components, specifically the light ends that
are used in the characterization process

Basis
For this module, you will be building on the case that you saved at
the end of the Getting Started Module.
1. Open the case that you saved at the end of the Getting Started
Module.
2. Click the Enter Basis Environment button to return to the
Enter Basis
Environment icon Basis environment.
3. Go to the Oil Manager tab and click the Enter Oil

Environment button. You can also press the Oil Environment
button on the tool bar. The oil characterization view appears.
Oil Environment icon
Figure 2
5.11
Adding Assay Data

On the Oil Characterizations view:
1. Select the Assay tab.
2. Click the Add button.
3. The Input Data tab of the Assay view appears.
4. In the Name cell, change the assay name to Res-Assay.
5. In the Bulk Properties cell, use the drop-down list to select
Used.
6. From the Assay Data Type drop-down list, select TBP.
7. Once the correct type is chosen, additional options should
appear. In the Light Ends cell; use the drop-down list to select
Input Composition. The other cells will not be used in this
example.
8. Select the Light Ends radio button in the Input Data group.
9. Specify the Light Ends Basis as Mole %. Note that the
default basis for Light Ends is Liquid Volume %; this must be
changed before the data is entered.
10. Enter the following data.
For this component... Enter this Mole %...

Nitrogen 0.48
H2S 0.00
CO2 0.87
Methane 41.83
Ethane 8.87
Propane 7.11
i-Butane 1.47
n-Butane 3.75
i-Pentane 1.25
n-Pentane 1.63
n-Hexane 0.00
H2O 0.00
11. Select the Distillation radio button. Change the assay basis
from Mole to Liquid Volume.
12. Click on the Edit Assay button to enter the curve as shown
below, in either oC or oF, then click OK.
5.12
Figure 3
13. Select the Bulk Props radio button to enter the following bulk
property data:
The Molecular Weight is 79.6
The Standard Density is 0.6659 SG_60/60api
14. Click on the Light Ends Handling & Bulk Fitting Options
button, and un-check the option for Curve Incl L.E. for the
distillation curve. This is required because the curve data
(assay input data) supplied in Figure 3 does not include the
light ends components.
15. Once you have entered all of the data, click the Calculate
button. The assay status should change to Assay was
Calculated.
Once the assay is calculated, results are displayed on the Working
Curves tab. The working curves are regressed from the entered
data. The calculation of the blend will be based on these curves.
16. Close the Assay window to return the Oil Characterization
view. You should still be on the Assay tab of the view.
Cutting the Assay

Once the Assay has been calculated, you can cut the Assay into
individual hypocomponents.
1. Move to the Cut/Blend tab of the Oil Characterization view.
Click the Add button to create a new Blend.
5.13
2. In the Name cell, change the name from the default, Blend-1 to
Res-Fluid.
3. From the list of Available Assays (there should only be one),
select Res-Assay and click the Add--> button. This adds the
Assay to the Oil Flow Information table on the Data tab, and
a blend (cut) will automatically be calculated. The Blend is
calculated using the default cut option, Auto Cut.
4. Instead of using the default Auto Cut option, change the Cut
Option selection to User Points and change the Number of
Cuts to 5.
The results can be viewed on the Tables tab of the Blend view.
Figure 4
What are the two lowest boiling points for the hypocomponents?
_____________________________________________________
Installing the Oil in the

Flowsheet
The final step of the characterization is to transfer the
hypocomponent information into the flowsheet.
1. Go to the Install Oil tab of the Oil Characterization view. The
blend, Res-Fluid appears in the Oil Install Information group.
5.14
2. In the Stream Name column, enter the name, GasWell 4, to

which the oil composition will be transferred. UniSim Design will
assign the composition of your calculated Oil and Light Ends
into this stream, completing the characterization process.
3. Return to the Basis Environment by clicking the Return to
Basis Environment button.
When you return to the Basis Environment, the hypocomponents
that you have generated in the Oil Characterization are placed in
the current fluid package. Hypocomponents are named according
to the blend group to which they belong and their Normal Boiling
Point. For example, a component named NBP[0]94* was generated
by the first blend (sequentially numbered within square brackets)
in the case and has a boiling point of 94C.
View the fluid package and examine the individual hypothetical
components which make up your oil.
Save your case!
5.15

Once you have calculated a blend, you can examine various
property and flow summaries for the generated hypocomponents
that represent a calculated oil.
In the Oil Environment, open the view for the blend, Res-Fluid.
Tables Tab
The Tables tab of the Blend contains various information,
representing the oil and the components. From the Table Type
drop-down, you can select different information to display.
Component Properties. When this is selected, choose
either Main Properties or Other Properties from the
Table Control.
Main Properties. Provides the normal boiling point,
molecular weight, density, and viscosity information for
each component in the oil.
Other Properties. Provides the critical temperature,
critical pressure, acentric factor, and Watson K factor for
each individual hypocomponent.
Component Breakdown. For the input light ends and each
hypocomponent, this provides individual liquid volume %,
cumulative liquid volume %, volume, mass, and mole flows.
Molar Compositions. Provides the molar fractions of each
light ends component and each hypocomponent in the oil.
Oil Properties. Choose the Basis (Mole, Mass, Liquid
Volume) and then the property you want to display.
Distillation. Provides TBP, D86, D86 Corr, D1160 Vac,
and D1160 Atm curves for the oil.
Other Properties. Provides critical temperature, critical
pressure, acentric factor, molecular weight, density, and
viscosity ranges for the oil.
User Properties. Gives all user property curves for the
oil.
Oil Distributions. Provides tabular information of how your
assay would be distributed in a fractionation column. You
can use several kinds of standard fractionation cuts or user
defined cuts.
5.16
Property Plot Tab

UniSim Design can plot various properties versus liquid volume,
mole, or mass percent distilled.
Figure 5
On the Property Plot tab, from the Basis drop-down list, select
Mass, Mole, or Liquid Volume for the X-axis.
From the Property drop-down list, choose the property to be
plotted on the Y-axis.
Distillation. You can plot one or more of the following: TBP,
D86, D86 (Crack Reduced), D1160 (Vac), D1160 (Atm), or
D2887.
By clicking on the
Molecular Weight
Clone and shelf this
plot button, the current Density
plot is copied, renamed
and stored. Cloned
Viscosity
plots are accessed and Critical Temperature
viewed from the Plot
Summary tab. Critical Pressure
Acentric Factor
User Properties
Distribution Plot Tab

The Distribution Plot helps in predicting column products.
5.17
The basis for the graphical comparison is made from the Basis
drop-down list of three options: Liquid Volume, Mole, and Mass.
The fractionation cut is selected using the radio buttons in the Cut
Input information group. There are four options:
Straight Run. The Straight Run cut displays the crude
column cuts: Off Gas, LSR Naphtha, Naphtha, Kerosene,
Light Diesel, Heavy Diesel, Atm Gas Oil and Residue.
Cycle Oil. The Cycle Oil cut displays the Cat Cracker cycle
oils: Off Gas, LC Naphtha, HC Naphtha, LCGO, ICGO, HCGO,
The existing cut and Residue Oil.
temperatures can be Vacuum Oil. The Vacuum Oil cut displays the vacuum
edited any time by
typing the desired value column cuts: Off Gas, LVGO, HVGO, and five VAC Residue
in the Cut Input ranges.
Information table. If
User Custom. The User Custom cut allows for the definition
changes are made to
the information in any of customized temperature ranges. If changes are made to
of the fractionation the information in any of the standard fractionation cuts,
cuts, the radio button the radio button will automatically switch to User Custom.
will automatically switch
to User Custom.
Composite Plot Tab

The Composite Plot tab allows you to visually check the match
between the input assay data and the calculated property curves.
Use Composite Curves to check the accuracy of the input assay
data against the hypocomponent properties. The choice for the
graphical comparison is made from the Property drop-down list.
TBP or ASTM Distillation Curve
Molecular Weight Curves
Mass Density Curves
Viscosity Curves
User Property Curve
5.18
Viewing the Stream in the

Simulation
1. Leave the Oil Environment to return to the Basis Environment.
2. Enter the Simulation Environment
3. If you see a message about HOLDING mode (Figure Figure 6),

answer No.
Figure 6
Answering Yes to this

message will place the
solver in Holding mode,
meaning no calculations
will be performed until
the solver is activated
via the green traffic
light. 4. Move to the Workbook to view the stream that you created:
GasWell 4. You can view the stream composition on the
Composition page.
If you determine that some of the hypocomponents parameters
need to be recalculated, you can return to the Oil Environment at
any time to make changes.
Add the following parameters to the stream GasWell 4:
Temperature = 35C (95F)
Flow rate = 545 kgmole/h (1200 lbmole/hr)
Pressure = 4405 kPa (639 psia)
Save your case!
5.19
Exploring the
Simulation
Exercise 1: Composite Plot
You have characterized the assay, specified two bulk properties
(Molecular Weight and Density); the hypocomponents have been
generated, the assay cut and after installing the oil in the flowsheet
(simulation environment), you decide to go back to the oil
environment to examine the various Blend plots generated,
particularly the Composite Plot.
The Composite Plot can be used to check the accuracy of the
calculated hypocomponent properties against the input assay data.
Upon examination of the Composite Plot you observe the calculated
hypocomponent data does not match the input assay data you
provided at all.
Why doesnt the calculated hypocomponent data match the input

curve data supplied in Figure 3? Explain.
_____________________________________________________
_____________________________________________________
_____________________________________________________
_____________________________________________________
5.20
Exercise 2: BP Curves
Utility
The Boiling Point Curves Utility enables you to obtain the results of
a laboratory style analysis for selected simulation streams. This
utility is generally used in conjunction with characterized oils from
the Oil Manager. The BP Curves Utility calculates simulated
distillation data, including TBP, ASTM D86, D86 (Corr), D1160
(Vac), D1160 (Atm), and D2887, as well as critical property data
for each cut point and cold property.
One way to access

The BP Curves Utility is useful for comparing whether there is a
utilities is by pressing good match between the calculated output data and the user
the CTRL U hot key to supplied input data. The object for the analysis can be a stream, a
open the Available phase on any stage of a tray section, or one of the phases in a
Utilities view.
separator, condenser, or reboiler.
From the Simulation Environment, add a BP Curves Utility to
stream GasWell 4, and compare the results with the input curve
data previously provided in Figure 3.
Are the results from the BP Curves Utility a good match for the
input assay data supplied in Figure 3? Why?
_____________________________________________________
_____________________________________________________
_____________________________________________________
_____________________________________________________
Save your case!
5.21
Challenge
Recall that the BP Curves Utility is useful for comparing whether
there is a good match between the calculated output data and the
user supplied input data.
In Exercise 2, it was observed that the calculated hypocomponent
property data did not match the input curve data (Figure 3) at all
because the input assay data did not include light ends, while the
calculated data did.
To allow a true comparison, generate a BP curve for stream
GasWell 4 which does not contain any light ends and compare the
results with the input assay data.
Using a Component Splitter to remove the light ends from the
stream will facilitate this exercise.
The Component Splitter is an operation that separates a material
feed stream into two component streams based on the parameters
and component split fractions that you supply.
Note: specifying product stream flash parameters (vapour fraction,
temperature and/or pressure), and an energy stream is not
required to obtain the resulting BP curve.
What are the calculated temperatures of the fluid without light

ends, at the 50% and 75% cut points?
_____________________________________________________
How do the results of the BP Curves utility applied to a stream
without Light Ends compare to the input assay data supplied in
Figure 3?
_____________________________________________________
5.22
Two-Stage Compression 6.1
6. Two-Stage
Compression

4526.06.R430.01
6.2 Two-Stage Compression
6.2
Workshop
This example demonstrates a typical application of the recycle
operation. Feed gas enters the compressor station at 35C (95F)
and 1725 kPa (250 psia). The gas is to be delivered at 6900 kPa,
and it is to be compressed in two stages. Each stage consists of a
knockout drum, a compressor, and a cooler. Liquids from each
separator are recycled back to the previous stage, after the
pressure has been reduced. A pipe segment is added to the
process product stream, and overall material and energy balance
checks are performed using UniSim Designs Simulation Balance
Tool.
Learning Objectives
Use the recycle operation in UniSim Design
Choose suitable tear locations for recycles
Add and specify a pipe segment
Use the Simulation Balance Tool
Prerequisites
Before beginning this module you need to know how to add
streams and operations.
6.3
Process Overview
Process Overview
6.4

Basis
1. Start a new case, set up a fluid package using the
Peng-Robinson EOS with the following components:
Nitrogen i-Butane
CO2 n-Butane
Methane i-Pentane
Ethane n-Pentane
Propane n-Hexane
Starting the Simulation

2. Add a new Material stream with the following values:

Name To Compression
Molar Flow 5000 kgmole/h (11000 lbmole/hr)
Nitrogen 0.0075
CO2 0.0147
Methane 0.5069
Ethane 0.1451
Propane 0.0725
i-Butane 0.0652
n-Butane 0.0578
i-Pentane 0.0515
n-Pentane 0.0431
n-Hexane 0.0357
6.5
Build the Simulation

without the Recycle
Operations
3. Install a Mixer with the following values:

Connections
Name Mixer 1
Inlet To Compression
Outlet To LP Sep
Parameters
Pressure Assignment Equalize All
4. Add a Separator with the information shown below:

Connections
Name LP Sep
Inlets To LP Sep
Vapour Outlet LP Sep Vap
Liquid Outlet LP Sep Liq
5. Add a Compressor with the following values:

Connections
Name Stage 1
Inlet LP Sep Vap
Outlet Stage 1 Out
Energy Stage 1 HP
Parameters
Adiabatic Efficiency 75% (default)
Worksheet
Stage 1 Out, Pressure 3450 kPa (500 psia)
6.6
6. Install a Cooler with the values listed in the following table:

Connections
Name Stage 1 Cooler
Inlet Stage 1 Out
Outlet Cooler 1 Out
Energy Stage 1 Q
Parameters
Pressure Drop 0 kPa
Worksheet
Cooler 1 Out, Temperature 50C (125F)
7. Add a Mixer operation to your case.

Connections
Name Mixer 2
Inlet Cooler 1 Out
Outlet To IS Sep
Parameters
8. Install a Separator with the following information:

Connections
Name IS Sep
Inlet To IS Sep
Vapour Outlet IS Sep Vap
Liquid Outlet IS Sep Liq
6.7
9. Add a Valve with the following information.

Connections
Name LetDown 1
Inlet IS Sep Liq
Outlet LD1 Out
Worksheet
LD1 Out, Pressure 1725 kPa (250 psia)
10. Install a Compressor with the values shown below:

Connections
Name Stage 2
Inlet IS Sep Vap
Outlet Stage 2 Out
Energy Stage 2 HP
Parameters
Adiabatic Efficiency 75% (default)
Worksheet
Stage 2 Out, Pressure 6900 kPa (1000 psia)
11. Install a Cooler operation to the case.

Connections
Name Stage 2 Cooler
Inlet Stage 2 Out
Outlet Cooler 2 Out
Energy Stage 2 Q
Parameters
Pressure Drop 0 kPa
Worksheet
Cooler 2 Out, Temperature 50C (125F)
6.8
12. Add a Separator with the following values:

Connections
Name HP Sep
Inlet Cooler 2 Out
Vapour Outlet HP Sep Vap
Liquid Outlet HP Sep Liq
13. Install a Valve with the following information:

Connections
Name LetDown 2
Inlet HP Sep Liq
Outlet LD2 Out
Worksheet
LD2 Out, Pressure 3450 kPa (500 psia)
The only operations missing at this point are the Recycles.

14. Save your case as 4526.06.TwoStageCompression.usc
Save your case!
6.9
Installing the Recycles

The UniSim Design Recycle logical operation is used to solve looped
systems where downstream material is mixed back in upstream in
Recycle Icon the process.
UniSim Design employs a non-sequential solving method, which
allows information to be propagated both upstream and
downstream. This allows some looped systems to be solved
explicitly (particularly heat recycles, and refrigeration loops).
However for material recycles when downstream material is mixed
back in upstream, a Recycle operation is needed.
Recycles are sometimes The Recycle operation allows UniSim Design to solve looped system
also known as Tears. iteratively. A set of conditions are assumed and used to solve the
recycle loop. The assumed values are compared with the
calculated values and updated. This is repeated until the values
match within a specified tolerance. The Recycle operation allows
information to be transferred both forwards and backwards (i.e.
the assumed value to be in either the outlet or inlet stream),
although usually information is only transferred forwards (i.e.
assumed value in outlet). In this workshop the recycles will use
this mode of operation.
When the Recycle operation is first added, initial estimates need to

be provided for all the assumed values. Typically this is done by
allowing UniSim Design to solve before closing the recycle loop.
This is illustrated in the Workshop.
The following steps take place during the convergence process:
UniSim Design uses the conditions of the assumed stream
(usually outlet) and solves the flowsheet up to the
calculated stream (usually inlet).
UniSim Design then compares the values of the calculated
stream to those in the assumed stream.
Based on the difference between the values, UniSim Design
modifies the values in the calculated stream and passes the
modified values to the assumed stream.
The calculation process repeats until the values in the
calculated stream match those in the assumed stream
within specified tolerances.
6.10
Examine streams LD1 Out and LD2 Out. Can the values in these
streams be used as the guess for the Recycle outlet?
_____________________________________________________
LD1 Out LD2 Out
Temperature
Pressure
Flow
Is Composition Known?
Notice that both LetDown Valve outlets (also the Recycle Inlets)
are known. This will be a good starting point for the Assumed
stream (the guess of the Recycle).
15. Add the first Recycle by double-clicking on the Recycle icon in

the Object Palette.
Recycle icon
6.11
Connections Page
16. Supply the Name, Feed and Product information as shown:
Figure 1
Parameters Tab
Figure 2
6.12
UniSim Design allows you to set the convergence criteria or

tolerance for each of the Recycle variables. In addition, the
direction of transfer of information can be set to Forwards or
Backwards, or Not Transferred. In general you will want to
leave the transfer as Forwards. In this example, leave everything
The smaller the at the default.
tolerance value, the
tighter the tolerance.
Generally it is a good
idea to start with the
default tolerance until
Numerical Page
you have a converged This page contains the numerical options for the Recycle, which
solution and then
tighten the tolerance.
control how it is solved numerically.
Figure 3
Monitor Tab
This page displays convergence information as the calculations are
performed. Any variable that changes between iterations is
displayed in this table. In order to view plots of variables as they
change during the calculation of the recycle, you must select the
variables to view on the Setup page.
6.13
Worksheet Tab
The Recycle Worksheet page displays the Inlet and Outlet stream
information. In this instance, notice that the Inlet and Outlet
streams have the same values. This is because before we installed
the Recycle, the Inlet stream was already calculated by UniSim
Design. When the Recycle was connected, the known Inlet
conditions were automatically passed to the Outlet stream to serve
as the starting guess.
17. Install the second Recycle with the following information:

Connections
Inlet LD2 Out
Outlet RCY 2 Out
The final step to solving the flowsheet is to connect the Recycle

Outlets as Inlets to Mixer1 and Mixer2. Once this is done, the
flowsheet will begin solving.
18. Attach RCY 1 Out as a feed to Mixer 1.

This can be done from 19. Attach RCY 2 Out as a feed to Mixer 2.
the Design tab,
Connections page of the
Mixers, or from the PFD
using attach mode. Save your case!
6.14

Examine the convergence process for the Recycles.
Open the Recycle property view and look at the Monitor tab. How
many iterations did each Recycle need to converge?
_____________________________________________________
Look at the Worksheet tab for each Recycle. How close are the
Inlet and Outlet stream variables?
_____________________________________________________
Are the vapour fractions identical for the Inlet and Outlet?
_____________________________________________________
RCY-1 RCY-2
Inlet Vf
Outlet Vf
In the next section you will use the Simulation Balance Tool to
examine the simulation results in more detail.
6.15
Simulation Balance Tool

The Simulation Balance Tool allows the user to perform overall
mass and energy balance checks on their simulation. It can reveal
modeling errors even if the simulation appears to be fully
converged.
The Simulation Balance Tool can be used to:
Check the mass and energy balances across the entire
model or constituent sub-flowsheets or unit operations
Find hidden errors caused by, for example, convergence
failures, numerical tolerances or user input errors
Once run the Simulation Balance Tool also provides an Overall
Mass Balance Monitor to give a live indication of the status.
Accessing the Simulation Balance

Tool
There are two ways to access the Simulation Balance Tool:
From the Tools menu, by selecting Simulation Balance
Double-click on the Overall
Tool
Mass Balance Monitor on From the Overall Mass Balance Monitor on the status bar
the status bar.
Setting the Simulation Balance

Tool Parameters
The Setup tab is used to set the Simulation Balance Tool
tolerances and configuration (Figure 4).
6.16
Figure 4
Tolerance Settings
The Tolerance Settings are used to specify which balances to
perform and the checking tolerance used by the Simulation Balance
in the validation.
The Component Balance Option group is displayed only when
Component Balance is checked. This option allows component
balances to be performed either for all components or for just a
single component.
Configuration Options
The Simulation Balance Tool includes three configuration options
controlled by checkboxes:
1. Run the Simulation Balance Tool Always
When this option is checked, the Simulation Balance Tool
automatically runs following any change to the flowsheet. If not
checked, the Simulation Balance Tool will not recalculate
automatically.
6.17
2. Include Feed and Product streams within Sub-

Flowsheets in balancing of Sub-Flowsheets
When this option is checked, any feed streams or product
streams inside sub-flowsheets which are not connected to
streams on the parent flowsheet are taken into consideration
when performing the balances for that sub-flowsheet.
3. Include Non-physical Feed Streams (Multiple Stream
Connections or Exported Column Streams)
When this option is checked non-physical streams, such as
multiple stream connections (single streams connected to
multiple unit operations) or exported column streams are
properly accounted for by counting each as a separate stream.
Recalculate Flowsheet
The Simulation Balance Tool also includes a command button
Recalculate Flowsheet. Clicking this button will force UniSim
Design to recalculate the entire flowsheet.
Preferences Options
The Simulation Balance Tool setup defaults can be defined in the
UniSim Design session Preferences on the Case Tools tab,
accessed via the Tools menu, by selecting Preferences (Figure
5).
Figure 5
6.18
These preferences will apply when a Simulation Balance Tool is first

added to a simulation case.
Ticking the Run Simulation Balance Tool Always checkbox in the

preferences will cause the Simulation Balance Tool to be added to
all new cases that are created and also to any old cases that are
loaded. It is recommended to make this setting.
Viewing and Understanding the

Simulation Balance Tool Results
Results from the Simulation Balance Tools are reported on five
tabs:
Summary Tab General

The Summary Tab, General view displays all unit operations
where the specified balances exceed the specified tolerances:
Figure 6
The table gives the following information about the operations:

Flowsheet the unit operation's parent flowsheet
Type - the UniSim Design object type of the unit operation
6.19
Name - the unit operation name. You can double-click on

the name to bring up the property view of the unit operation
Mass Error - the mass balance error in both absolute and
relative values
Mole Error - the molar balance error in both absolute and
relative values
Energy Error - the heat balance error in both absolute and
relative values
Comp Error - the component molar balance error in both
absolute and relative values
Comp Name - the name of the component with the highest
component molar balance error
Cells shown with a red background indicate values which exceed
the specified tolerances. Blank cells means the balance error is
less than the specified tolerances.
The results can be grouped by Flowsheet and Type as well as
sorted based on the other columns. The grouping and sorting by
name is done in ascending order while the rest of the sorting is in
descending order.
In Figure 6 the Summary tab, General view shows a simulation
where there are two Recycle unit operations on the Main flowsheet
which have errors higher than the specified tolerances. RCY-1 has
absolute and relative mass, mole and energy balance errors. RCY-2
has relative mole and absolute energy balance errors.
6.20
Summary Tab Detailed

The Summary tab, Detailed view gives a unit by unit balance
summary in terms of both absolute and relative errors.
Figure 7
Select the unit operation of interest by selecting the Flowsheet

containing the unit operation and then clicking the unit operation
name under Operations.
Double-clicking on the unit operation name will bring up the
property view for that unit operation.
Figure 7 shows a simulation where a Recycle unit operation named
RCY-2 on the main flowsheet is selected. The detailed balance
shows the absolute energy balance error across this operation is
4893 kJ/h. Cells shown with a red background indicate values
which exceed the specified tolerances.
Feed/Products Tab
The Feeds/Products tab displays the overall mass and energy
flows of all the feed and product streams in the simulation, and the
overall balance errors.
The Overall Balance Errors are displayed using the following
color-coding:
Green - the errors are within the specified tolerances
6.21
Red - the errors exceed the specified tolerances
Figure 8
Figure 8 shows a simulation where there are overall mole and

component mole balance errors higher than the tolerance on both
an absolute and relative basis. The absolute mass balance and
absolute energy balance errors are also outside their defined
tolerances.
Transitions tab
The Transitions tab shows all Transition objects with balance
errors larger than the specified tolerances. Transition objects
include recycle unit operations, flowsheet boundaries and stream
cutters.
6.22
Figure 9
The results can be displayed with the Transitions objects listed by

row (Normal) or by column (Transpose)
Figure 9 shows the Transitions tab from a simulation where there
are two Recycle unit operations in the Main flowsheet which have
errors higher than the specified tolerances.
Adjust/Recycle Tab
The Adjust/Recycle tab lists all Adjust and Recycle unit
operations in the simulation with their key parameters.
6.23
Figure 10
Figure 10 shows the Adjust/Recycle tab from a simulation with

two Recycle unit operations and one Adjust unit operation (which
has a status of Ignored).
Alerts tab
The Alerts tab lists all unit operations in the simulation which have
warning or error status messages:
6.24
Figure 11
Figure 11 shows the Alerts tab from a simulation with eight alert
messages, two from separators, two from valves, two from recycle
unit operations, one from a compressor and one from a cooler.
6.25
Overall Mass Balance

Monitor
The Overall Mass Balance Monitor provides a live check of the
Simulation Balance Tool status. It has four possible values:
Balance Tool indicating the Simulation Balance Tool has
not been run (Figure 12):
Figure 12
Balance Needs Re-running indicating the Simulation

Balance Tool needs re-running following some change to the
flowsheet (Figure 13):
Figure 13
6.26
Mass Balanced indicating the overall mass balance is

satisfied to within the tolerances specified by the user
(Figure 14):
Figure 14
Mass Not Balanced indicating the overall mass balance

is outside the tolerances specified by the user (Figure 15):
Figure 15
6.27
Workshop
The Simulation Balance Tool provides a mechanism to check for
material and energy balances within UniSim Design flowsheets as a
means to gain a rapid overview of all entities which could be the
source of a flowsheeting error even if a flowsheet has a status of
converged.
In this workshop you will use the Simulation Balance Tool to check
the results of the simulation you built at the beginning of this
module.
1. Open the case you saved at the end of the last section
(4526.06.TwoStageCompression.usc)
2. From the Tools menu, select Simulation Balance Tool
3. On the Setup tab, enable the mass, mole, energy and
component balances with the tolerances as shown in Figure 16:
Figure 16
6.28
4. Investigate the results of the Simulation Balance Tool using the

Summary, Feeds/Products, Transitions, Adjust/Recycle
and Alerts tabs
Are there any unit operations with balance errors? Which ones?
_____________________________________________________
Why do you think these unit operations have balance errors?
_____________________________________________________
Can you think of a way to reduce the errors?
_____________________________________________________
5. Go to the Adjust/Recycle tab

6. Change the Comp Sensitivity for all Recycle unit operations in
your model to 0.1
7. Investigate the results of the Simulation Balance Tool using the
Summary, Feeds/Products, Transitions, Adjust/Recycle
and Alerts tabs
Did reducing the sensitivity resolve the balance errors?

_____________________________________________________
How did it achieve this?
_____________________________________________________
Save your case!
6.29
Pipe Segment
The pipe segment is used to simulate a wide variety of piping
situations ranging from single or multi-phase plant piping with
rigorous heat transfer estimation, to large capacity looped pipeline
problems. It offers the common pressure drop correlations
developed by Gregory, Aziz, and Mandhane, and Beggs and Brill. A
third option, OLGAS, is also available as a gradient method. In
addition there are a large number of speciality pressure drop
correlations available. Consult the On-line Help and the Manual for
more information on these methods. Four levels of complexity in
heat transfer estimation allow you to find a solution as rigorously
as required while allowing for quick generalized solutions to well-
known problems.
The pipe segment offers four calculation modes:

Pressure Drop
Length
Flow
Pipe segments that
Diameter
traverse undulating
terrain are subdivided The appropriate mode will automatically be selected depending on
further into a number of
segments with elevation
the information supplied. In order to solve the pipe, you must
points assigned at supply enough information to completely define both the material
locations where there is balance and the energy balance.
a significant slope
change.
Adding a Pipe Segment

In this simulation, we will be using one individual pipe segment
operation in the gathering system. In addition, the Pipe operation
will contain multiple segments to represent the various elevation
rises and drops.
Schedule 40 steel pipe is used throughout and the pipe is buried at
a depth of 1 m (3 ft). All pipes are uninsulated.
1. Double-click on the Pipe Segment icon from the Object

Palette.
Pipe Segment icon
Design tab - Connections page

On the Connections page, the Inlet (Feed), Product, and Outlet
(Energy) stream connections are made.
2. Complete the Connections page as shown below:
6.30
Figure 17
Design tab - Parameters page

On this page, you can select the Pipe Flow Correlation which will
be used for two-phase (VL) flow calculations. The options are:
Aziz, Govier & Fogarasi
Baxendell & Thomas
Beggs & Brill
Duns & Ros
Gregory, Aziz, Mandhane
Additional licenses are Hagedorn & Brown
required to access the OLGAS2000_2P
OLGAS correlations.
These use 3rd party OLGAS2000_3P
correlations from SPT
Orkiszewski
Group.
Poettman & Carpenter
Slurry Pipe Correlation
Tulsa99
UniSim, Liquid Slip
UniSim, Homogeneous Flow
6.31
For single phase streams, the Darcy equation is used for pressure
drop predictions, regardless of the correlation selected on the
Parameters page. The Darcy equation is a modified form of the
mechanical energy equation, which takes into account losses due
to frictional effects as well as changes in potential energy.
3. In this example the flow through the pipe is single phase
vapour so the Darcy equation will be used, hence leave the
selected Pipe Flow Correlation as Beggs and Brill which is
the default. If required the pressure drop for the pipe can be
supplied on the Parameters page. In this example, it will be
left empty and calculated.
Rating tab - Sizing page

On the Sizing page, you construct the length-elevation profile for
the Pipe Segment. Each pipe section and fitting is labeled as a
segment. To fully define the pipe section segments, you must also
specify pipe schedule, diameter, material and # of increments.
Horizontal pipe sections

PIPE-100 is broken into three segments.
have an Elevation of 0. 4. Add the first segment to the pipe unit operation by clicking the
Positive elevation
indicates that the outlet Append Segment button. Specify the following information for
is higher than the inlet. the segment:

Fitting/Pipe Pipe
Length 1021 m (3350 ft)
Elevation Change 0 m (0 ft)
5. To specify the diameter, click the View Segment button.

6. Select Schedule 40 as the Pipe Schedule.
7. From the Available Nominal Diameters group, select 203.2
mm (8 inch) diameter pipe and click the Specify button. The
UniSim Design contains
Outer and Inner Diameter will be calculated by UniSim Design.
a database for three 8. Use the default Pipe Material, Mild Steel and the default
pipe schedules: 40, 80, Roughness, 4.572e-5 m (0.0018 inch). Close the window.
and 160.
9. Two more segments are needed to complete the pipe branch.
In this cell Enter Enter

Segment 2 3
Fitting/Pipe Pipe Pipe
Length 700 m (2297 ft) 600 m (1969 ft)
Elevation -5 m (-16.40 ft) 12 m (39.37 ft)
6.32
In this cell Enter Enter

Schedule 40 40
Nominal 203.2 mm (8 inch) 203.2 mm (8 inch)
Diameter
When all three segments have been added and defined, the view
should look like this:
Figure 18
The Pipe segment is not yet able to solve because we have not
specified any information about the heat transfer properties of the
pipe.
Rating tab - Heat Transfer page

On this page, you select the method that UniSim Design will use
for the heat transfer calculations.
You have the option of specifying the heat transfer information By
Segment or Overall.
By Segment. You specify the Ambient Temperature and
HTC (Heat Transfer Coefficient) for each segment that was
created on the Sizing page.
Overall. One of four heat transfer methods will be applied
to the whole pipe segment.
6.33
Duty Method. If the Overall heat duty of the segment is

known, the energy balance can be calculated immediately.
Each increment is assumed to have the same heat loss.
Stream Temperatures. If both inlet and outlet and
ambient temperatures are specified, a linear profile is
assumed and the overall heat duty can be calculated.
Overall Heat Transfer Coefficient Specified. If the
overall HTC and Ambient Temperature are known, then
rigorous heat transfer calculations are performed on each
increment of the pipe.
Heat Transfer Coefficient Estimation. The overall HTC
can be calculated from its component parts.
Inside Film Convection
Outside Conduction/Convection
Conduction through Insulation
For the pipe in this simulation, use the Estimate HTC method.
10. On the Rating tab, click on Heat Transfer.
11. Switch to the Overall HTC radio button, and enter an Ambient
Temperature of 5C (40F).
12. Switch to the Estimate HTC radio button, and complete it as
follows:
Figure 19
What is the outlet pressure of PIPE-100?

_____________________________________________________
6.34
Pipe Segment Summary

The Profiles page on the Performance tab provides a summary
table for the segments which make up the Pipe Segment. The
distance, elevation and number of increments are displayed for
each segment.
By clicking the View Profile button, you access the Pipe Profile
view, which consists of a Table tab and a Plot tab. The Table tab
shows the following information for each increment along the Pipe
Segment:
Length
Elevation
Pressure
Temperature
Heat Transferred
Flow Regime
Liquid Holdup
Friction Gradient
Static Gradient
Accel Gradient
Bulk Liquid and Vapor Reynolds Number
Bulk Liquid and Vapor Velocity
The Plot tab graphically displays the profile data that is listed on
the Table tab. The parameters plotted are selected by radio
buttons.
Open the property view for PIPE-100 and examine the Table and
Plots on the Profiles page of the Performance tab.
6.35
Figure 20
Figure 21
Save your case!
6.36
Advanced Modeling
Because the Recycle operation is a mathematical representation of
a physical process, its location in a simulation is a particularly
important one. The location of the tear stream can often
determine success or failure to converge a recycle.
Positioning the Recycle

Operations for Optimum
Performance
When a user is deciding on a tear (Recycle) location, the first
choice is often in the actual recycling stream. This is an acceptable
choice if only one Recycle operation is being used. However, if
more than one block is being used a better location may reduce the
calculation time needed to solve the simulation.
Careful choice of recycle position can also reduce the number of

Recycle operations that are required. This will reduce the solution
time and reduce the number of points at which an error can be
introduced if the tolerance is too large.
Try to locate Recycles:
A very poor choice of a
tear stream is a stream To define multiple streams (i.e. before Tees, after Mixers). See
with an Adjust Answers to the four subsequent Recycle Positioning Exercises are
operation controlling provided at the end of the module in the Answer Key section.
one of its variables.
Exercise 1. This means fewer recycle operations are
needed.
In streams with fixed conditions (i.e. cooler and heater
outlets). This means fewer variables need to be iterated on.
To avoid conflicts with Adjust operations.
In major flow streams. These are likely to be more stable.
6.37
Recycle Positioning
Exercises
Answers to the four subsequent Recycle Positioning Exercises are
provided at the end of the module in the Answer Key section.
Exercise 1
Examine the following PFD. This flowsheet has three physical
recycles and three UniSim Design Recycle operations.
What is the minimum number of recycle operations that are

needed?
_____________________________________________________
Where should the recycle operation(s) be positioned?
_____________________________________________________
_____________________________________________________
Figure 22 Exercise 1
6.38
Exercise 2
Assume the condenser outlet stream is fully defined (except flow
rate), the chiller duty and outlet conditions are known, the
pressure drops across the condenser and chiller are known, and
the stage 1 compressor outlet pressure is known.
This flowsheet is the refrigeration loop with economizer from the
Challenge at the end of Module 2 of the UniSim Design 4526
course.
How many recycles are needed in this flowsheet, where should

they be placed, and why?
_____________________________________________________
_____________________________________________________
_____________________________________________________
6.39
Exercise 3
Assume that the feed stream (To Refrig) is fully defined, all
pressure drops are known for the exchanger and the chiller as well
as the LTS separator feed temperature.
This flowsheet is the refrigerated gas plant from Module 3 of the
UniSim Design 4526 course.

_____________________________________________________
_____________________________________________________
_____________________________________________________
6.40
Exercise 4
Assume the Feed is completely defined. Also known are the shell
and tube side pressure drops for E-100 and E-101, and the
temperatures of streams 3 and 4.
This flowsheet is really an extension of the PFD in Exercise 3. A
column and overall material recycle have been appended to the
gas plant flowsheet.
Note that columns MUST have a fully specified feed stream to

solve. (The only exception is that from UniSim Design R380.1
onwards pressure can be propagated backwards from the column
to the feed stream).

_____________________________________________________
_____________________________________________________
_____________________________________________________
6.41
Exercise 5: Compressor
Curves
After finishing the simulation, your boss provides you with a set of
Compressor Curves for the Stage 2 Compressor which now exists
in the field. This compressor operates at a speed of 5000 rpm and
performs as per the manufacturers curves given below. Will the
existing Compressor be able to achieve the outlet pressure you
As well as entering want (i.e. 6900 kPa), or will you have to add a third stage of
curves of head vs flow compression?
you can also enter
pressure ratio vs flow.
If speed is unknown, Flow, ACT [m3/min
Head [m (ft)] Polytropic Efficiency
you can also estimate (ACFM)]
the compressor design
30 (1000) 6000 (19670) 74
speed (use the Design
Speed for this 55 (2000) 5950 (19500) 75
Compressor button on
the Design tab 95 (3400) 5800 (19000) 75.25
Parameters page). 140 (5000) 5500 (18000) 74.5
This feature uses a
correlation from the 175 (6200) 4800 (15700) 72
GPSA handbook. 205 (7300) 3360 (11000) 68
Consult the UniSim
Design Operations
Guide manual for more
details.
Challenge
You complain to your boss that your simulation takes too long to
converge on your computer because of the recycles and use this
opportunity to petition for a new high speed computer. Your boss
has a look at your simulation and denies your request on the basis
that you can reduce your convergence time by eliminating one of
the recycle unit operations in the simulation. Is your request
justified or is your boss correct?
6.42
Answer Key
Exercise 1
Examine the PFD above. This flowsheet has three physical recycles
and three UniSim Design recycle operations. What is the minimum
number of recycle operations that are needed?
One. There are 3 separate loops and they overlap in stream 1.
(Hint. Visualize the separate loops in the system. Which stream is
included in all the loops?)
Where should the recycle operation(s) be positioned?
At the outlet of the mixer.
Exercise 2
There is no need for a recycle operation in this refrigeration loop flowsheet
due to the positioning of the specifications.
Exercise 3
Again there is no need for a recycle operation. Since the LTS separator
feed stream has a known temperature and pressure it is fully defined even
though the Gas-Gas exchanger hasnt completely solved, hence the
separator can solve and then the exchanger can solve.
6.43
Exercise 4
There is no need for a recycle in the small loop containing the two
exchangers and separator V-101 because the pressures and temperatures
in streams 3 and 4 are known, hence stream 4 can flash fully before the
exchangers are solved.
However, the column will not be able to solve unless its feed stream is
fully defined, hence a single recycle is needed somewhere in the main loop
- for example in stream 1, 7 or 9.
6.44
Acid Gas Sweetening with DEA 7.1
7. Acid Gas
Sweetening
with DEA

4526.07.R430.01
7.2 Acid Gas Sweetening with DEA
7.2
Workshop
In this example, a typical acid gas treating facility is simulated. A
water-saturated natural gas stream is fed to an amine contactor.
For this example, Diethanolamine (DEA) at a strength of 28 wt% in
water is used as the absorbing medium. The contactor consists of
20 real stages. The rich amine is flashed from the contactor
pressure of 6900 kPa to 620 kPa before it enters the rich/lean
amine exchanger, where it is heated to the regenerator feed
temperature of 95C. The regenerator also consists of 20 real
stages. Acid gas is rejected from the regenerator at 50C, while
the lean amine is produced at approximately 110C. The lean
amine is cooled and recycled to the Contactor.
Learning Objectives
Simulate Amine towers in UniSim Design
Supply tray dimensions to calculate component efficiencies
for Amine towers
Use the Set operation
Use the Spreadsheet
Prerequisites
Before beginning this section you need to be able to start a new
case from scratch, add and contact streams and unit operations
and be familiar with the column recycle operations.
7.3
Process Overview
Process Overview
7.4
Column Overview
Contactor
Figure 1
Regenerator
Figure 2
7.5

Basis
For this case, you will be using the DBRAmine property package
The DBRAmine property with the following components:
package does not allow
hypothetical
components. Nitrogen n-Butane
H2S i-Pentane
CO2 n-Pentane
Methane n-Hexane
Ethane H2O
Propane DEAmine
i-Butane
1. Set up a new case, using the
2. DBRAmine property package with the components above. Use

the Kent-Eisenberg model.
Amines Property Package

The Amines package contains the thermodynamic models
You will also find Amine
developed by D.B. Robinson & Associates for their proprietary
Pkg in the list of
Property Packages. This amine plant simulator, AMSIM. Their equilibrium acid gas solubility
is an older and kinetic parameters for aqueous alkanolamine solutions in
implementation which contact with H2S and CO2 have been incorporated into this property
has been superseded by
package. The Amines property package has been fitted to
the DBRAmine package.
It is maintained only for extensive experimental data gathered from a combination of D.B.
compatibility when Robinsons in-house data, several unpublished sources and
loading old cases. numerous technical references. For more information, refer to
Appendix C of the Simulation Basis Manual.
The Amines package incorporates a specialized stage efficiency
model to permit the simulation of columns on a real tray basis. The
stage efficiency model calculates H2S and CO2 component stage
efficiencies based on the tray dimensions and the calculated
internal tower conditions for both absorbers and strippers.
7.6
Adding the Basics

Adding the feed streams
3. Add a new stream for the inlet gas with the following values:

Name Sour Gas
Molar Flow 1250 kgmole/h (25 MMSCFD)
Nitrogen 0.0016
H2S 0.0172
CO2 0.0413
Methane 0.8692
Ethane 0.0393
Propane 0.0093
i-Butane 0.0026
n-Butane 0.0029
i-Pentane 0.0014
n-Pentane 0.0012
n-Hexane 0.0018
H2O 0.0122
DEAmine 0.0
4. Add a second stream for the lean amine feed to the amine
contactor with the following values:

Name DEA to Contactor
Make sure you enter Pressure 6850 kPa (994 psia)
the DEAmine and H2O
compositions on a Std Ideal Liq Vol Flow 43 m3/h (190 USGPM)
weight (mass) basis. Component Mass Fraction
H2O 0.72
DEAmine 0.28
7.7
The values for the stream DEA to Contactor will be updated once
the recycle operation is installed and has calculated.
Adding the Physical Unit

Operations
Separator Operation
Any free water carried with the gas is first removed in a Separator
operation, FWKO TK.
5. Add a Separator and provide the following information:

Connections
Name FWKO TK
Inlet Sour Gas
Vapour Outlet Gas to Contactor
Liquid Outlet FWKO
What is the flow rate of water in FWKO?

_____________________________________________________
Contactor Operation
The amine contactor is simulated using an Absorber operation in
UniSim Design.
6. Add an Absorber column operation with the following

specifications:

Connections
The Input Experts are
toggled on and off from Name DEA Contactor
the Simulation tab of No. of Stages 20
the Preferences view.
Top Stage Inlet DEA to Contactor
Bottom Stage Inlet Gas to Contactor
Ovhd Vapour Outlet Sweet Gas
7.8

Bottoms Liquid Outlet Rich DEA
Pressures
Top 6850 kPa (994 psia)
Bottom 6900 kPa (1001 psia)
Estimates
Top Temperature 40C (100F)
Bottom Temperature 70C (160F)
The Amines property package requires that real trays be used in

the contactor and regenerator operations. To model this in
UniSim Design, component specific efficiencies are required for H2S
and CO2 on a tray by tray basis. These proprietary efficiency
calculations are provided in the column as part of the Amines
package. Tray dimensions must be supplied to enable this feature.
Tray dimensions enable component specific efficiencies to be
calculated by estimating height of liquid on the tray and the
residence time of vapour in the liquid. To supply the dimensions for
Amines calculations, switch to the Parameters tab, Amines page.
7. Enter the following Tray Section dimensions:

Amines
Weir Height 0.025 m (0.082 ft)
Weir Length 1.0 m (3.3 ft)
Tray Diameter 1.2 m (4.0 ft)
Figure 3
7.9
8. Run the Column.

9. Once the Column has converged, move to the Efficiencies
page on the Parameters tab.
10. Select the Component radio button in the Efficiency Type
group to view the component efficiencies.
Figure 4
11. Switch to the Worksheet tab to view the concentrations of H2S

and CO2 in the product streams from the column.
What is the concentration of H2S and CO2 in the Sweet Gas?
H2S__________________________________________________
CO2__________________________________________________
Valve Operation
Rich DEA from the Contactor is directed to a Valve, VLV-100,
where the pressure is reduced to 620 kPa (90 psia), which is close
to the Regenerator operating pressure.
12. Add a Valve with the following values:

Connections
Inlet Rich DEA
Outlet DEA to Flash TK
7.10

Worksheet
Pressure, DEA to Flash TK 620 kPa (90 psia)
Separator Operation
Gases which are flashed off from Rich DEA are removed using the
rich amine flash tank, Flash TK, which is installed as a Separator
operation.
13. Add a Separator with the information shown below:

Connections
Name Flash TK
Inlets DEA to Flash TK
Vapour Outlet Flash Vap
Liquid Outlet Rich to L/R
Heat Exchanger Operation

Regen Feed is heated to 95C (200F) in the lean/rich exchanger,
L/R HEX, prior to entering the Regenerator, where heat is applied
to break the amine-acid gas bonds, thereby permitting the DEA to
be recycled to the contactor.
14. Add a Heat Exchanger with the following values:

Connections
Name L/R HEX
Tube Side Inlet Rich to L/R
Tube Side Outlet Regen Feed
Shell Side Inlet Regen Bttms
Shell Side Outlet Lean from L/R
Parameters
Tubeside Delta P 70 kPa (10 psi)
Shellside Delta P 70 kPa (10 psi)
Heat Exchanger Model Exchanger Design (Weighted)
Worksheet
Regen Feed, Temperature 95C (203F)
7.11
Regenerator Operation
The Amine Regenerator is modeled as a Distillation Column. There
are 20 real stages - 18 stages in the Tray Section plus a Reboiler
and Condenser. The component efficiencies for this tower are
assumed to be constant at 0.8 for H2S and 0.15 for CO2. The
efficiencies of the Condenser and Reboiler must remain at 1.0, so
Damping Factors will
have no effect on only stages 1-18 should have efficiencies entered for them. A
problems where the Damping Factor of 0.4 will provide a faster, more stable
heat and spec error convergence. The Damping Factor controls the step size used in
does not converge.
the outer loop when updating the thermodynamic models in the
Certain columns require inner loop.
the use of a damping
factor.
15. Add a Distillation column with the following information:
Amine Regenerators,
TEG Strippers and Sour
Water Strippers use In this cell... Enter...
damping factors in the
Design\Connections
0.25 0.5 range.
Name Regenerator
No. of Stages 18
Feed Streams / Stage Regen Feed / 4
Condenser Type Full Reflux
Ovhd Vapour Outlet Acid Gas
Bottoms Liquid Outlet Regen Bttms
Reboiler Energy Stream Rblr Q
Condenser Energy Stream Cond Q
Parameters\Solver
Fixed Damping Factor 0.40
Solving Method Legacy Inside-Out
Parameters\Profiles
Condenser Pressure 190 kPa (27.5 psia)
Condenser Delta P 15 kPa (2.5 psi)
Reboiler Pressure 220 kPa (31.5 psia)
Top Stage Temperature 100C (210F)
Reboiler Temperature 125C (260F)
You will need to click Parameters\Efficiencies
the Reset H2S, CO2
button before you can CO2 0.15
enter the specified H2S
H2S 0.8
and CO2 efficiencies
7.12

Design\Monitor
Overhead Rate (Estimate) 75 kgmole/h (1.5 MMSCFD)
Reflux Ratio (Estimate) 1.5
Design\Monitor
Remember to activate
the Condenser Column Temperature, 50C (120F)
Temperature and Condenser
Reboiler Duty
Column Duty, Reboiler 1.3e7 kJ/h (1.2e7 Btu/hr)
specifications once they
are added.
An alternative 16. Run the column.
specification that could
be used is the
Component Recovery
for DEA, because all of
the DEA (100%) should
be recovered in the
bottom product stream.
7.13
Mixer Operation
Water make-up is necessary, since water is lost in the Absorber
and Regenerator overhead streams. A Mixer operation combines
the lean amine from the Regenerator with a water makeup. These
streams mix at the same pressure.
17. Add a new stream.
The Mixer will adjust
the water flow rate to
achieve the circulation In this cell... Enter...
rate. An Adjust
Connections
operation could have
been used but is not Name Makeup H2O
necessary.
H2O 1.0
18. Add a Mixer with the following information:

Connections
Inlets Makeup H2O
Lean from L/R
Outlet DEA to Cool
Parameters
Worksheet
Std Ideal Liq Vol Flow, 43 m3/h (190 USGPM)
DEA to Cool
What is the flow rate of Makeup H2O?

_____________________________________________________
7.14
Cooler Operation
19. Add a Cooler with the values given below:

Connections
Name Cooler
Feed Stream DEA to Cool
Product Stream DEA to Pump
Energy Stream Cooler Q
Parameters
Pressure Drop 35 kPa (5 psi)
Pump Operation
20. Add a Pump with the following information:

Connections
Inlet DEA to Pump
Outlet DEA to Recycle
Energy Pump Q
Worksheet
Temperature, DEA to 35C (95F)
Recycle
7.15
Adding Logical Unit

Operations
Set Operation
The Set is a steady-state operation used to set the value of a
specific Process Variable (PV) in relation to another PV. The
relationship is between the same PV in two like objects; for
Set icon instance, the temperature of two streams, or the UA of two
exchangers.
21. Double-click on the Set icon. Complete the Connections tab as
shown in the following figure.
Figure 5
22. Go to the Parameters tab. Set the Multiplier to 1, and the

Offset to -35 kPa (-5 psi) as shown below:
7.16
Figure 6
Recycle Operation
The Recycle installs a theoretical block in the process stream. The
feed into the block is termed the calculated recycle stream, and the
product is the assumed recycle stream. The following steps take
Recycle icon place during the convergence process:
and solves the Flowsheet up to the calculated stream.
stream to those of the assumed stream.
modifies the values in the assumed stream.
within specified tolerances.
In this case, the lean amine (DEA to Contactor) stream which was
originally estimated will be replaced with the new calculated lean
amine (DEA to Recycle) stream and the Contactor and Regenerator
will be run until the recycle loop converges.
23. Double-click on the Recycle icon. On the Connections tab
select the connections from the drop-down lists as follows:
7.17
Figure 7
24. Switch to the Parameters tab. Ensure the tab is as shown in

the figure below:
Figure 8
The smaller the

Sensitivity the tighter
the tolerance.
Save your case!
7.18

The incoming sour gas contained 4.1% CO2 and 1.7% H2S. For our
inlet gas flow rate of 1250 kgmole/h (25 MMSCFD), a circulating
solution of approximately 28 wt% DEA was used to remove H2S
and CO2. The conventional pipeline gas specification is no more
than 2.0 vol% CO2 and 4 ppm (volume) H2S.
To calculate vol ppm
multiply liquid volume
fraction by 1 million. What is the C02 vol% in the Sweet Gas?
_____________________________________________________
What is the H2S vol ppm level?
_____________________________________________________
Have the pipeline gas specifications been met?
_____________________________________________________
7.19
Advanced Modeling
Concentrations of acid gas components in an amine stream are
typically expressed in terms of loadings of amine. Loadings are
defined as moles of the particular acid gas divided by moles of the
circulating amine. The Spreadsheet in UniSim Design is well-suited
for this calculation. Not only can the loadings be directly calculated
and displayed, but they can be incorporated into the simulation to
provide a control point for optimizing the amine simulation.
25. Add a spreadsheet using the following variables for the loading
calculations:
Figure 9
7.20
26. On the Spreadsheet page, enter the formulae for the loading
calculations.
Spreadsheet
D2 =b2/b1
D3 =b3/b1
D5 =b5/b4
D6 =b6/b4
The acid gas loadings can be compared to values recommended by

D.B. Robinson.
Maximum Acid Gas Loadings

(moles acid gas / moles of amines)
CO2 H2S
MEA, DEA 0.50 0.35
DEA 0.45 0.30
TEA, MDEA 0.30 0.20
27. Enter appropriate text labels for the imported

variables/formulae. Your spreadsheet should appear as shown.
Figure 10
7.21
Exploring the
Simulation
Exercise 1: Doubling the
Flow rate
You just received a phone call from the plant manager at a
neighboring gas plant. They are having a problem with their
contactor and must shut down. You have agreed to take on their
gas for processing, which doubles the flow rate of gas to your
plant. Make the necessary changes to handle the upset.
7.22
Natural Gas Dehydration with TEG 8.1
8. Natural Gas
Dehydration
with TEG

4526.08.R430.01
8.2 Natural Gas Dehydration with TEG
8.2
Workshop
At the wellhead, reservoir fluids generally are saturated with water.
The water in the gas can present some problems:
formation of solid hydrates can plug valves, fittings, or
pipes
the presence of water along with H2S or CO2 can cause
corrosion problems
water can condense in the pipeline causing erosion or
corrosion problems
Generally, a dehydration unit is used in gas plants to meet a
pipeline specification. There are several different processes
available for dehydration: glycols, silica gel, or molecular sieves.
The natural gas industry commonly uses tri-ethylene glycol (TEG)
for gas dehydration where low gas dew point temperatures are
required, such as in the design of offshore platforms in the Arctic
or North Sea regions or for other cryogenic processes.
In this example, the water dew point spec for the dry gas is -10C
(-14F) at 6155 kPa (893 psia).
Learning Objectives
Model a typical TEG dehydration unit
Determine water dew point for a gas
Prerequisites
Before beginning this section you need to be able to add streams,
operations and columns.
8.3
Process Overview
Process Overview
8.4
Column Overview
TEG Contactor
Figure 1
TEG Regenerator
Figure 2
8.5

Basis
For this case, you will be using the Peng-Robinson EOS with the
following components:
Nitrogen i-Butane
H2S n-Butane
CO2 i-Pentane
Methane n-Pentane
Ethane H2O
Propane TEGlycol
1. Set up a new case, using the Peng-Robinson property

package with the components above.
Starting the Simulation

Adding the feed streams
2. Add a Material stream for the inlet gas with the following
values:

Name Inlet Gas
Molar Flow 500 kgmole/h (10 MMSCFD)
Nitrogen 0.0010
H2S 0.0155
CO2 0.0284
Methane 0.8989
Ethane 0.0310
8.6

Propane 0.0148
i-Butane 0.0059
n-Butane 0.0030
i-Pentane 0.0010
n-Pentane 0.0005
H2O 0.0000
TEGlycol 0.0000
3. Add a second Material stream for the TEG feed to the TEG
Contactor with the listed values.

Name TEG Feed
Remember to enter
these compositions as Std Ideal Liq Vol Flow 0.5 m3/h (2 USGPM)
mass fractions!
Component Mass Fraction
H2O 0.01
TEGlycol 0.99
The values for the stream TEG Feed will be updated once the
Recycle operation is installed and has calculated.
Mixer Operation
The composition of the natural gas stream has been provided on a
water-free basis. To ensure water saturation, the gas is mixed with
water prior to entering the Contactor.
4. Add a Mixer to mix the Inlet Gas and Water to Saturate
streams.
8.7

Connections
Name Saturate
Inlets Inlet Gas
Water to Saturate
Outlet Gas + H2O
Parameters
Automatic Pressure Equalize All
Assignment
Worksheet
Water to Saturate, 0.5 kgmole/h (1.1 lbmole/hr)
Flow rate
Water to Saturate, 100% Water
Composition
Water to Saturate, 30C (85F)
Temperature
What is the vapour fraction of the stream Gas+H20? (It should be

less than 1.0 to ensure saturation)
_____________________________________________________
Separator Operation
Any free water carried with the gas is first removed in a separator
operation, FWKO.
5. Add a Separator and provide the following information:

Connections
Name FWKO TK
Inlets Gas + H2O
Vapour Outlet Gas to Contactor
Liquid Outlet FWKO
8.8
How much water is removed by the Separator?

_____________________________________________________
What is the hydrate temperature of Gas to Contactor?
_____________________________________________________
Contactor Operation
The TEG Contactor can now be simulated.
6. Add an Absorber column operation with the following
specifications and Run the column.

Connections
Name TEG Contactor
No. of Stages 8
Top Stage Inlet TEG Feed
Bottom Stage Inlet Gas to Contactor
Ovhd Vapour Outlet Dry Gas
Bottoms Liquid Outlet Rich TEG
Pressure
Top 6190 kPa (897 psia)
Bottom 6200 kPa (900 psia)
Valve Operation
The Rich TEG stream is flashed across the valve, VLV-100. The
outlet pressure will be back calculated.
7. Add a Valve with the following values:

Connections
Inlet Rich TEG
Outlet LP TEG
Heat Exchanger Operation

Regen Feed is heated to 105C (220F) in the lean/rich exchanger,
L/R HEX, before entering the Regenerator.
8.9
8. Add a Heat Exchanger with the following values:

Connections
Name L/R HEX
Tube Side Inlet Regen Bttms
Tube Side Outlet Lean from L/R
Shell Side Inlet LP TEG
Shell Side Outlet Regen Feed
Parameters
Tubeside Delta P 70 kPa (10 psi)
Shellside Delta P 70 kPa (10 psi)
Worksheet
Regen Feed, Temperature 105C (220F)
Regen Feed, Pressure 110 kPa (16 psia)
8.10
Regenerator Operation
The TEG Regenerator is simulated as a Distillation Column. The
TEG Regenerator consists of a condenser, a reboiler and one ideal
stage.
9. Add a Distillation Column to the case.

You can turn off the Connections
Column Input Experts
in Tool/Preferences on Name TEG Regenerator
the Simulation tab by
No. of Stages 1
un-checking the Use
Input Experts box. Inlet Stream Regen Feed
Condenser Type Full Reflux
Ovhd Vapour Outlet Sour Gas
Bottoms Liquid Outlet Regen Bttms
Condenser Energy Stream Cond Q
Reboiler Energy Stream Reb Q
Pressures
Delta P Cond 2 kPa (1 psia)
Specs
First Spec - Column Temperature
Stage Condenser
Spec Value 102C (215F)
Status Active
Second Spec - Column Temperature
Stage Reboiler
Spec Value 205C (400F)
Status Active
Third Spec - Reflux Ratio
Spec Value 1.0 Molar
Status Estimate
Fourth Spec - Column Draw Rate
Draw Sour Gas @ COL2
Spec Value 1 kgmole/h (0.02 MMSCFD)
Status Estimate
8.11
10. Set the Damping method (on the Solver page of the
Parameters tab) to Adaptive. This will result in much faster
convergence for this column.
11. Run the Column.
Mixer Operation
TEG is lost in small quantities in the top products of the columns,
so a makeup stream is required to ensure that the material balance
is maintained.
12. Add a Material Stream with the following information:

Connections
Name Makeup TEG
Component Mass Fraction
Dont forget to enter
H2O 0.01
the compositions as
mass fractions! TEG 0.99
13. Add a Mixer with the following information:

Connections
Inlets Makeup TEG
Lean from L/R
Outlet TEG to Pump
Parameters
Automatic Pressure Equalize All
Assignment
Worksheet
Std Ideal Liq Vol Flow, 0.5 m3/h (2 USGPM)
TEG to Pump
What is the flow rate of Makeup TEG?

_____________________________________________________
8.12
Pump Operation
A pump is installed to raise the pressure of the TEG before it enters
the Contactor.
14. Add a Pump with the following information:

Connections
Inlet TEG to Pump
Outlet Pump Out
Energy Pump Q
Worksheet
Pump Out, Pressure 6275 kPa (910 psia)
Heat Exchanger
A second heat exchanger is added to cool the TEG returning to the
Contactor.
15. Add a Heat Exchanger with the following information:

Connections
Tube Side Inlet Pump Out
Tube Side Outlet TEG to Recycle
Shell Side Inlet Dry Gas
Shell Side Outlet Sales Gas
Parameters
Tube Side Delta P 70 kPa (10 psi)
Shell Side Delta P 35 kPa (5 psi)
Worksheet
TEG to Recycle, 50C (120F)
Temperature
Recycle Operation
The Recycle installs a theoretical block in the process stream. The
feed into the block is termed the calculated recycle stream, and the
product is the assumed recycle stream. The following steps take
Recycle icon place during the convergence process:
8.13

and solves the Flowsheet up to the calculated stream
stream to those of the assumed stream
modifies the values in the assumed stream
within specified tolerances
The specifications in the lean TEG (TEG Feed) stream which were
originally estimated will be replaced by values updated by the
recycle. The recycle will control iterations of the loop until it
converges.
16. Double-click the Recycle icon from the Object Palette. On the
Connections tab select the connections from the drop-down
boxes as depicted below:
Figure 3
17. Switch to the Variables page on the Parameters tab.

Complete the page as shown in the figure below. Tolerances for
Flow, Enthalpy and Composition need to be tightened.
8.14
Figure 4
The TEG concentration

is very high so it is
necessary to tighten the
tolerances, especially
for composition, to
ensure an accurate
solution.
Hydrate Formation Utility

There are three ways to attach utilities to streams.
Click on the Tools menu and select Utilities. The
Available Utilities view appears
Press Ctrl U and the Available Utilities view appears
Double-click a stream. On the Attachments tab, select
Utilities. Click Create and the Available Utilities view
appears
Attach a Hydrate Formation

Utility to Stream Sales Gas
18. Press Ctrl U and in the Available Utilities view, select the
Hydrate Formation Utility and click on the Add Utility
button. If the utility is not already associated with a stream,
then the Hydrate Formation Utility view appears.
19. Click Select Stream and select the Sales Gas. Click OK.
20. Switch to the Performance tab. Here you will see the
Equilibrium Phase reported as Vapour Phase.
8.15
Figure 5
What is the hydrate temperature of the Sales Gas stream?

_____________________________________________________
How does this compare with the hydrate temperature of the Gas to
Contactor stream?
_____________________________________________________
Save your case!
8.16

One of the criteria used to determine the efficiency of a
dehydration facility is the water dew point of the dry gas. First, all
traces of TEG must be removed from the stream being tested
because TEG affects the water dew point. This is accomplished by
the use of a Component Splitter. A property correlation is used to
calculate the water dew point temperature.
21. Add a Component Splitter with the following values:

Component Splitter
icon
Connections
Name Remove TEG
Inlet Sales Gas
Overhead Outlet TEG Only
Bottoms Outlet Water Dew point
The Component Splitter Energy Split Q

does not do a flash to
separate components. Parameters
The separation is
TEG Only, Temperature 35C (95F)
specified by the user.
Water Dew Point, Temperature 35C (95F)
Stream Specifications Equalize All Stream Pressures
Splits
Stream TEG Only, TEG 1.0
Stream TEG Only, all other components 0.0
The next step is to add a Water Dew Point Property Correlation to

the Water Dew Point stream.
22. Double-click on the Water Dew Point stream.
23. Open the Properties page on the Worksheet tab. The
property correlations displayed are controlled using the buttons
at the bottom of the Properties page.
Figure 6
8.17
24. Click the Append New Correlation button. The Correlation

Picker view appears displaying all the available correlations in
a tree format.
Append New
Correlation icon 25. From the list of available correlations click on the + symbol to
view additional sub-items for the Gas branch. Select the Water
Dew Point correlation (see Figure 7) and click Apply. Close
the Correlation Picker. The new correlation is added to the
bottom of the list.
Figure 7
26. Locate the Water Dew Point [Gas] property correlation that
was just added.
8.18
Figure 8
What is the water dew point temperature of the Sales Gas stream?
Does it meet the required spec: -10C (-14F) at 6155 kPa (893
psia)?
_____________________________________________________
8.19
Exploring the
Simulation
Exercise 1: Stripping Gas
The addition of stripping gas (a slip stream from Sales Gas) will
enhance the ability of the Regenerator to remove water from the
rich TEG. Take note of the current concentration of TEG in the
Regen Bttms stream.
1. Add a Tee operation to split the Sales Gas into two streams.
The strip gas stream is specified as follows:
Flow = 50 kgmole/h (110 lbmole/hr)
The stream pressure is 6155 kPa which is too high for the
Regenerator.
2. Add a heater to prepare the Strip Gas stream to be a feed to
the Regenerator. Specify the following parameters for the
heater:
Product stream name = SG to Regen
Product stream temperature = 70C (160F)
Product stream pressure = 110 kPa (15 psia)
3. Connect stream SG to Regen as a feed to the Regenerator
Reboiler.
Does the TEG concentration in Regen Bttms increase?

_____________________________________________________
Note: the sales gas now exceeds the dew point specification easily.
8.20
Reporting in UniSim Design 9.1
9. Reporting in
UniSim Design

4526.09.R430.01
9.2 Reporting in UniSim Design
9.2
Introduction
Once you have finished a simulation, or during analysis, you may
wish to obtain reports of the data that you have input and that
UniSim Design has generated. Reporting data in UniSim Design can
be achieved in a number of ways, such as:
Report manager
Print to File option
Copy-Paste with Labels option
Workbook and PFD customization
Excel utilities
Learning Objectives
Once you have finished this module, you will be able to customize
reports in UniSim Design using the Report Manager, customize the
PFD and the workbook to display selected data and install and run
an Excel utility to view data from the workbook.
Prerequisites
Familiarity with the UniSim Design interface
Ability to modify the workbook in UniSim Design
Knowledge of Microsoft Excel
9.3
Report Manager
The Report Manager in UniSim Design allows the user to include
data from all unit operations and streams in a UniSim Design case
in any order. This information can then be printed. The information
available through the Report Manager is the same information
available if one prints a unit operation or stream report directly
from the UniSim Design case.
Exercise 1
1. Open the solution case from the Gas Dehydration with TEG
module, 4526.08.NGDehydrationTEG.usc.
2. Go to the Tools menu, and select Reports. You are now in the
Report Manager.
3. Click the Create button to create a new report. You are
Information about
operations and streams presented with a new window that allows you to customize the
in UniSim Design used content of the report.
for printing is contained
in objects called 4. Click the Insert Datasheet button to obtain a menu of all the
Datasheets. information available in the case that can be included in the
report:
Figure 1
5. You can filter the lists by object type or by name, using the
radio buttons at the top of the window. In this case, leave the
radio button on Pick a Specific Object by Name.
6. Leave the Flowsheets selection at Case (Main) and choose
stream Sales Gas under the Objects list. You will notice that
all the datablocks available for stream Sales Gas have been
selected by default in the Available Datablocks window:
9.4
Figure 2
7. The only information we want to include in our datasheet is the

stream conditions, so you need to click on the + next to the
Worksheet option and deselect all the remaining selections
(e.g. Properties, Composition and K values). You will also
need to deselect Attachments, Dynamics, PSD Properties,
User Variables, Status and Notes:
Figure 3
8. Click the Add button to add the Conditions for stream Sour
Gas to the report. You will notice that the report now contains
the conditions for stream Sales Gas.
9. Now, add the TEG Regenerator column Design Datablock to
the report in the same way. (HINT: the Flowsheets selection
must be left at Case(Main) in order to select the Design
Datablock for a column.)
10. In the report manager, you can add information from the
workbook as well as from streams and Unit operations. Add the
Unit Ops page from <Workbook Main> to the report.
11. We are now finished adding datasheets to the report. Close the
Select Datablocks for Datasheet window.
9.5
12. On the Report Manager window, you can see that you can
change the order in which the datasheets are presented in the
report, and you can edit the content as well. In addition, you
can change the name of the report. Change the name of this
report to Dehy Report.
Figure 4
13. You can also change the format and layout of the report, as
well as the unit set used in the report. Click on the
Format/Layout button and select the Field Unit Set. This unit
set will now always be associated with this report. Close the
window.
14. You are now ready to Print or Preview the report. In this
case, we will not print the report to paper, but we will preview
it. Click the Preview button to see what the report would look
like when printed.
Note that user specified

values are identified on
Save your case!
the printout with an
asterisk, * ,next to
them.
9.6
Customizing the
Workbook
This topic was briefly covered in Modules 1 and 2. Additional detail
will be provided here.
While the report manager is a useful interface for generating
reports, it is not necessarily the most convenient method for
transferring results from UniSim Design to Microsoft Excel or other
tools, or even for printing the results directly from UniSim Design.
It is often easier to customize the workbook to generate the data
set that is desired and then use the copy-paste functionality in
UniSim Design to transfer the data to Excel for further editing or
printing from Excel.
In addition to the normal copy-paste functionality, UniSim Design
also allows the user to copy the data to the clipboard and include
the data labels as well. This greatly reduces the formatting that is
required to produce useful datasheets in Excel. This option is
accessed by selecting Copy with Labels on the Edit menu, or by
using the hot-key combination CTRL+SHIFT+C.
Additional Workbook
Customization
In modules 1 & 2, you learnt how to add an additional workbook
tab with customized properties. In this module, we will look at
some additional options.
Sorting the Streams

The default behavior in UniSim Design is for the workbook to be
sorted in the order that the objects were created. For example, the
first stream that was added to the PFD will be the first stream in
the workbook and the last stream created will be the last stream in
the workbook. There may be times when you would prefer an
alternate arrangement. This is easily accomplished with UniSim
Design. With the workbook open, simply open with Workbook
menu and select Order/Hide/Reveal Objects. Alternatively, you
can right-click on any object in the workbook and choose the
Order/Hide/Reveal option in the list that appears.
9.7
By clicking on the Ascending or Descending radio buttons in the

Sorting group box, you can direct UniSim Design to automatically
sort the objects alphabetically in ascending or descending order. If
you want to manually sort the objects to a particular order, simply
choose the Manual option.
The Order/Hide/Reveal window also allows you to hide streams
or operations that you are not interested in seeing. Simply select
the stream that you want hidden and press the Hide---> button,
the stream will move over to the Hidden column and will no longer
appear on the active tab of the workbook. For example, if you hide
the FWKO stream from the Material Streams workbook, it will still
be displayed on the other tabs (e.g. Composition).
Exercise 2
Continue to use the TEG Dehydration case used in Exercise 1.
1. Open the workbook and create a new Material Streams tab
following the procedure outlined in module 2.
2. Change the name of the new tab to Feeds&Products. Change
the properties that are displayed to include: Temperature,
Pressure, Mass Flow, and the Component Mass Flows for all the
components.
3. Use the Order/Hide/Reveal Objects view to hide all streams
except for the feed and product streams. The following streams
should be visible: Gas to Contactor, Sales Gas, Sour Gas,
Makeup TEG.
4. Use this workbook to ensure that the inflow of TEG (Makeup
TEG) and the outflow of TEG (Sales Gas and Sour Gas) are
equal.
5. Use the Copy With Labels option in UniSim Design to copy
this workbook tab to an Excel worksheet.
6. Add the Feeds&Products workbook tab to the PFD as a
workbook table.
Another useful feature of the workbook is the ability to reorganize
the data in an inverted format. In this format, the property names
are listed along the top of the workbook and the object information
is listed in rows instead of in columns. To view this format, simply
un-check the Horizontal Matrix checkbox in the lower left hand
corner of the workbook.
This alternate view is an easy way to view the data and also
provides another way of transferring the data to or from Excel.
9.8
Adding Process Information

to the PFD
There are several ways to include process information with the
PFD. One way, as was demonstrated in the previous exercise, is to
add workbook tables to the PFD. You can also add stream tables to
the PFD to display information on specific streams.
Some other methods include:

SHIFT+P, SHIFT+T, SHIFT+N, SHIFT+M, SHIFT+F, SHIFT+R hot-
keys to display pressure, temperature, name, mass flow, mole
flow, and description, respectively.
By using a custom colour scheme you can highlight streams with
certain characteristics. For example, you can set up a colour
A full list of all hot-keys scheme to show all streams below 50 oC in the normal colour,
is available by choosing streams above 50 oC, but below 100 oC, in a cautionary colour
the Hot-key list option (maybe yellow) and streams above 100 oC in a warning colour
on the Help menu.
(maybe red).
Exercise 3 - Adding a
Custom Colour Scheme
1. Open the PFD view in the current case, if it is not already the
active view.
Colour Scheme Icon
2. Click on the Colour Scheme icon in the upper right-hand
corner of the PFD window.
3. On the PFD Colour Schemes window that appears, click on
the Add a Scheme button.
4. The default variable is Temperature and we will use this
default in this exercise. Notice that there are several other
choices that we could also have used.
5. There are five colours that can be used. You can adjust the cut
points to create a colour scheme that will provide you with the
behavior that you desire. For this example, the lower three cut
points will not be changed. Only change the top cut point and
make it the same as the third cut point (100 oC or 212 oF). This
effectively reduces the colour scheme to a four colour system,
but this is fine for this case.
9.9
Once this coluor scheme is active, you should see that the hottest
streams on the PFD are shown in red and the cooler streams have
other colours. The red streams should be: Regen Bttms, Regen
Feed, Sour Gas, Lean From L/R, TEG to Pump, Pump Out.
It is obvious when the PFD is drawn with this scheme that we are
pumping a very hot stream. This may not be recommended as it
may require special insulation, materials, or seals in the pump. The
process may be improved if the pump were moved to a position
after the E-100 exchanger where the TEG stream is much cooler.
This change could reduce the capital cost of the pump and
potentially reduce the maintenance costs as well.
Creating Multiple PFD's

In UniSim Design, you have the capability of creating multiple
PFD's for a single case. This can be a useful feature for very large
cases, or for smaller cases when combined with additional colour
schemes.
To create an additional PFD, open the PFD menu from the menu
bar, and select Add a PFD.
This will create an additional PFD. With the additional PFD, you can
return it to the default colour scheme, or change the stream label,
or the positioning of the operations. You can also hide streams
and/or operations on the second PFD to focus on a specific area of
the flowsheet. Note, however, that if you delete streams or
operations on either PFD, they will be deleted from the model.
Streams or operations can be hidden on separate PFD's, but they
should not be deleted.
It is important to note that both the original PFD and the second
PFD are linked to the real time data. Anytime that the data is
changed, this change will be reflected immediately on both PFDs.
Copying the PFD

Now that we have examined the process for adding process
information to the PFD and changing the colour scheme on the
PFD, we should examine the process for copying the PFD from
UniSim Design into other applications like Microsoft ExcelTM or
WordTM.
9.10
This is a very simple process. With the PFD open in UniSim Design,
simply right-click on the background area. This will bring up the
'object inspection' window for the PFD. One of the options in this
menu is Copy Pane to Clipboard. Select this option and a second
window will appear; here you can choose the scaling factor. This
affects the size of the bitmap file that is copied to the clipboard.
Since it is possible to scale the graphic after it is imported into the
other application, it is not too critical which scaling factor that you
choose.
Once the pane is copied to the clipboard, go to the other
application (Word, Excel, Powerpoint, etc.) and paste (CTRL+V) the
clipboard image into that application.
The user should be aware that this process creates a static

'snapshot' of the PFD. Once the image is copied, it is no longer
linked to the live data and any changes made to the UniSim Design
case will not be reflected on the copied image.
Exercise 4
1. Follow the steps described above to create a second PFD in the
current case.
2. For the second PFD, select the default colour scheme and hide
all of the operations except for the two exchangers.
3. Now hide all of the streams expect for the 8 streams directly
connected to the two heat exchangers.
4. Change the stream label to show the stream's temperature
instead of the stream's name.
5. Change the name of the second PFD to HX Summary.
6. Finally, use the Copy Pane to Clipboard functionality to
transfer a snapshot of the modified PFD into Microsoft Excel.
9.11
Finding objects within

the model
Another useful tool for viewing data in UniSim Design is the
Simulation Navigator. This tool gathers all of the stream and
operation object property views into a common location.
To open the Simulation Navigator, either click on the Simulation

Navigator icon in the tool bar, or select Simulation Navigator
Simulation Navigator under the Flowsheet menu in UniSim Design.
Icon
Once the Simulation Navigator is open, you can see that all of
the operations and streams are grouped according to their
respective types. This allows you to quickly find streams if you
know the name of the stream. Likewise, it allows you to quickly
find the number of separators or columns in a model. Note that all
of the streams are listed here, including those that are not part of
the main flowsheet.
Now, the Simulation Navigator allows you to quickly view the
properties for a stream, if you know the stream's name. But, how
can you quickly find an object (stream or operation) on the PFD if
you only know the object's name? The Simulation Navigator and
the Workbook have a tool that is very useful for this exact task.
Once you have found the object with either the Simulation
Navigator or the Workbook, you can locate it on the PFD as
follows:
From the Simulation Navigator, click the Find button
located above the object tree (Figure 5)
From the Workbook right-click on the stream name and
select Find in PFD.
9.12
Figure 5
UniSim Design will open the PFD, and zoom into the PFD so that
the selected stream or operation is in the centre of the view and
the attached objects are also visible. This allows the user to zoom
out to see a larger area on the PFD, while keeping the selected
object in the centre of the view.
Alternatively if you have the PFD of a flowsheet open and you know
that somewhere on that PFD there is a stream or flowsheet you
want to locate you can right click on the PFD background and
choose Select Objects. Find the object you require on the
Select Objects window that appears. Press OK and note that now
the object you choose is selected and flashing. If you cannot see
the selected object press the HOME key on the keyboard to zoom
the PFD on that object.
9.13
Excel Tools for

Reporting
UniSim Design has a full OLE Automation interface. This feature
has been used to create a number of tools to allow interface
between UniSim Design and Excel. This module will focus on using
the Workbook dump macro.
1. Open the workbook in the UniSim Design case. Customize the
Material Streams tab to add the Component Mole Fraction of
Water and the Mass Density to each stream. Ensure that the
Material Streams page is the active page on the workbook.
2. Locate the file UniSim Design WorkbookDump 1.0.1.xls
from your Starter disk and copy it to the hard drive of your
machine. Any convenient folder is fine.
3. Double click on the Excel Spreadsheet to open it. Make sure
macros are enabled in Excel.
4. You will see that all the workbooks available in the currently
open case are listed in the window on the Excel spreadsheet. If
they are not, click the Refresh Flowsheet List button.
5. Select the workbook for Case(Main) by clicking once on it, so it
is highlighted in blue.
6. Click the Dump Workbook button. You will see the Material
Streams page of the workbook being recreated in Excel. The
user input values are shown in blue, in addition to having an
asterisk next to them.
7. Now, switch to UniSim Design and make the Compositions
page of the Workbook the active page. Return to Excel and click
the Dump Workbook button again. Now, the Compositions
page is shown in Excel.
9.14
Additional Excel Tools

Honeywell has other useful Excel tools:
UniSim Design Stream Reporter (USD-SR) allows material
stream conditions, properties and compositions to be easily
reported onto a spreadsheet to easily create a Heat and
Material Balance table, it also enables streams in different
cases to be conveniently compared.
USD-SR can be downloaded from the UniSim Design

Customer Support Centre at
http://unisim.supportportal.com.
UniSim Design Browser can be used to set up OLE

Automation links between UniSim Design and Excel without
the user needing to write any Automation code. The
Browser works by a series of custom Excel functions that
interact with UniSim Design, and a graphical front end to
simplify the writing of these functions. The functions can be
copied, pasted and manipulated as required without any
knowledge of VB programming.
UniSim Design Excel Interface Tool (USE-IT) can be used to

create and run case studies with UniSim Design with the
input and output data stored in Excel.
UniSim Design Browser and USE-IT can be installed from

the Honeywell UniSim Design Suite R430 DVD by using the
Optional UniSim Components option on the setup menu.
9.15
Answers to Questions QA.1
Answers to
Questions

4526.QA.R430.01
QA.2 Answers to Questions
QA.2
Chapter 1 Getting Started

Page Question Answer
12 Normal Boiling Point of C7+, C7 and 110C, 98.43C, 125.7C
C8 respectively
Ideal Liquid Density of C7+, C7 and 745.4 kg/m3, 686.8 kg/m3, 705.4 kg/m3
C8 respectively
Molecular Weight of C7+, C7 and 111.0, 100.2, 114.2
C8 respectively
22 Vapour Fraction of GasWell 2 @ 0.9872
7500 kPa and 10C
Dew Point Temperature of 11.52C
GasWell 2 @ 7500 kPa
Bubble Point Temperature of -34.29C
25 Critical Temperature and Pressure -11.98C, 8984 kPa
for GasWell 2 respectively
36 Using the Envelope Utility:
Critical Point for GasWell 1 -1.079C, 1.444e+004 kPa
(Read in the Utility Design and/or Performance tabs)
Cricondenbar (max pressure) for 1.630e+004 kPa
GasWell 1 (Read in the Utility Design and/or Performance tabs)
Bubble Point Temperature for Approximately -48C
GasWell 3 @ 6000 kPa (Read in the Utility Design and/or Performance tabs)
Dew Point Temperature for Approximately 98
GasWell 1 Temperature for 50% Approximately -32C
Quality @ 8000 kPa (Read in the Utility Design and/or Performance tabs)
Hydrate Formation Temperature for Approximately 23C
36 Using the Workbook: (i.e. do an exact flash in the appropriate stream)
Bubble Point Temperature for -48.03C
Dew Point Temperature for 98.15C
GasWell 1 Temperature for 50% -32.2C
Quality @ 8000 kPa
37 Using the Hydrate Formation
Utility:
Hydrate Formation Temperature for 21.1195C
QA.3

38 Challenge: - Add the Property Table Utility for GasWell 3
Dew and Bubble Point calculations - Variable 1 = Vapour Fraction, State (0, 1)
on GasWell 3, at varying pressures, - Variable 2 = Pressure, Incremental (100 10000 kPa)
using the Property Table Utility - Add Temperature as a Dep Prop
- Calculate
- On the Performance tab, view the table/plot for the points
Chapter 2
Propane Refrigeration Loop
6 Pressure of Stream 1 1720 kPa
10 Molar Flow Rate of Propane 107.9 kgmole/h
Pressure Drop across J-T valve 1469.20 kPa
Temperature of the valve outlet -19.21C
(Stream 2)
13 Compressor Energy in hp 218.521 hp
29 Chiller Duty (compressor running at Note: first remove the given/calculated Chiller Duty
90% of max 250 hp and 72% 9.885 e+005 kJ/h
efficiency)
29 Best Chiller Outlet Temperature This cannot be calculated directly. Since if the chiller outlet
achievable while still running the temperature is removed and the duty reentered the
Compressor at a reasonable simulation does not solve. This shows that UniSim Design
operating point (maintaining a cannot solve with every combination of variables, even
chiller duty of 1.5 MMBtu/hr) though the degrees of freedom of the problem is zero.
One way to do this is delete the compressor efficiency and
specify the chiller duty. Now specify a chiller outlet
temperature and manually iterate on this until the
calculated efficiency is reasonable. With this approach, a
temperature of -5 C gives an efficiency of 78.337%.
Alternatively specify the efficiency and the chiller outlet
temperature (hence calculate a chiller duty) and then use
an Adjust operation to vary the chiller outlet temperature
(the Adjusted Variable) until the chiller duty (the Target
Variable) is 1.5 MMBtu/hr. This gives a chiller outlet
temperature of -1.967 C with a 72% efficiency.
30 What effect, if any, does a 95/5 This blend is not as good a refrigerant and therefore less
mole % propane/ethane blend have efficient. This means to achieve the same chiller duty
on the refrigeration loop? requires a greater refrigerant flow rate and hence higher
Compressor and Condenser Duties.
30 Base Case: Flow = 107.9 kgmole/h
QA.4

Condenser Q = 1.587e+006 kJ/h
Compressor Q = 218.5 hp
New Case (5% C2, 95% C3): Flow = 111.0 kgmole/h
Condenser Q = 1.62e+006 kJ/h
Compressor Q = 230.9 hp
31 Challenge: Stage1 comp duty = 65.63 hp
After creating a two stage Stage2 comp duty = 112.33 hp
refrigeration loop by adding an Net Compression = 65.63 hp + 112.33 hp = 177.96 hp
Economizer, what is the net
compression in hp?
Chapter 3
Refrigerated Gas Plant
10 Flow rate of Gas to Chiller 1440 kgmole/h
11 What information is required for the Gas to LTS Temperature (the LTS Feed Temperature)
LTS separator to solve?
12 Pressure of Sales Gas 6125 kPa
Temperature of Sales Gas 10C
15 Dew Point Temperature -19.8C
Required dew point is -15C, is the Current dew point (-19.8C) is lower than the required
current dew point higher or lower? value of -15C
Assume pressure is fixed, what Mole Fraction (composition) also affects dew point.
other parameter affects dew point?
How can we change the dew point Since dew point pressure is fixed in the simulation, the dew
in the simulation? point temperature can be modified by changing the Chiller
outlet (Gas to LTS) temperature. A change in Chiller outlet
temperature will change the composition (phase fraction)
of the Gas to LTS stream (it is a two phase stream going to
the separator).
19 What is the Chiller Outlet -15.18C
Temperature to achieve the Dew
Point specification?
22 Flow rate of propane in the 156.9 kgmole/h
Refrigeration Loop Right click on sub-flowsheet icon and choose Open PFD to
view the Refrigeration Loop PFD.
23 Available UA for the Gas-Gas De-activate the Temp Approach spec and activate the UA
Exchanger is only 2e+005 kJ/C.h. spec. Go to the Details page of the Performance tab to
Making the necessary modifications view the temperature approach (Min. Approach) and LMTD,
to the exchanger design to achieve which have increased.
this UA; how do these modifications Min Approach = 7.301C (up from 5C)
QA.5

affect the LMTD and Temperature LMTD = 9.151C (up from 7.131C)
Approach?
23 Challenge: -Delete the chiller in the main PFD and in the sub-
Replace the single-sided cooler flowsheet
operation with the shell and tube -Add a shell and tube heat exchanger operation on the
exchanger that will actually be in main PFD
the plant. -Connect the streams from the main PFD to the shell side
of the new heat exchanger, and specify a Delta P of 35 kPa
-Connect the streams from the sub-flowsheet to the tube
side (on Design\Connections page of heat exchanger by
changing the tube side sub-flowsheet to the refrigeration
loop) and specify a Delta P of 7 kPa
26 What First Stage Compressor Outlet 800 kPa is the First Stage Compressor Outlet Pressure
Pressure (stream 4) will result in (stream 4) which results in 176.02 hp usage (the minimum
the minimum power usage in the power usage in the Refrigeration Loop).
Refrigeration Loop? This can be observed by clicking the Results button in the
Case Studies Setup window and selecting either Table or
Graph format.
Chapter 4
NGL Fractionation Train
13 Mole frac of Methane in DC1 Ovhd 0.97
15 Flow rate of the overhead product, 1350 kgmole/h
DC1 Ovhd.
16 Flow rate of C2 and C3 in DC2 Btm C2=0.66; C3=106.1 kgmole/h
Ratio of C2/C3 0.66/106.15 = 0.00626
You can also allow USD to calculate the ratio for you by
adding a component ratio spec. To do so follow the
instruction on page 16 (points 3, 4 and 5). Leave the
component spec inactive for now but notice that the
current value is calculated for you regardless.
17 Flow rate of DC2 Ovhd 307 kgmole/h
18 Mole Fraction of C3 in overhead and C3 in DC3 Dist = 0.9207
bottoms products C3 in DC3 Btm = 0.2547
22 Challenge 1: UA is dependent on both sides of a heat exchanger. The
UA of the De-Methanizer Reboiler? column reboiler is similar to a heater + separator; cant get
UA value from this configuration (can only get UA value
Create an internal stream in the from a proper heat exchanger).
column flowsheet that represents
the liquid that flows from the In column view (copy Reboiler tray 10):
bottom tray of the reboiler, which -Go to column runner, flowsheet tab, add internal stream
can then be added to a heat -Select stage 10-main, type = liquid, check Export so that
exchanger in the main flowsheet. the stream will appear in the main flowsheet, Run
Use steam to exchange heat with In main view:
-Add a heat exchanger with the following connections; tube
QA.6

the process. side inlet=(internal stream added), tube side outlet=2,
shell side inlet=1 (steam), shell side outlet=3, Delta P for
shell side is 5 psi and tube side is 0
Add a Set operation (live data):
-Target = stream 2 (tube side outlet temperature)
-Source = DC1 Btm
UA of De-Methanizer Reboiler:
-Open the heat exchanger view, Details page of the
Performance tab
UA* = 7.11e+04 kJ/C-h
*If using Weighted Heat Exchanger Model, which is
recommended since the steam is condensing
23 Challenge 2: -Delete the pressure specification in stream DC3 Feed
Given additional geometry/size and - In valve VLV-100:
operating data for valve VLV-100, -On Rating tab, Sizing page, set the Valve Manufacturer to
use the P-F Relation specification Universal Gas Sizing and characteristic to Linear
instead of Delta P.
- On the Design tab, Parameters page, select P-F Relation
Check that the valve stays within for Pressure Drop Parameters
the pressure range for stream DC3
Feed when operating at steady -Enter Valve Opening and Conductance
state. Stream DC3 Feed Pressure = 1653 kPa
The pressure for stream DC3 Feed is within the acceptable
range when operating at steady state (1600 1800 kPa)
Chapter 5
Oil Characterization
14 The two lowest boiling points for the NBP[0]94* @ 94C
hypocomponents NBP[0]186* @ 186C
20 Why doesnt the calculated The input assay data (Figure 3) does not include Light
hypocomponent data match the Ends, while the calculated data includes both
curve data supplied in Figure 3? hypocomponents and Light Ends.
21 Are the results from the BP Curves No, for the same reason.
Utility a good match for the input
assay data? Why?
22 Challenge: 50% Cut Point, TBP = 285.9C
Calculated temperatures at the 75% Cut Point, TBP = 387.2C
50% and 75% cut points
How do the results of the BP Curves Splitting the Light Ends from the hypocomponents using
utility without Light Ends compare the Component Splitter allows for a like for like comparison
to the input assay data? of the calculated hypocomponent data versus the input
assay data. The results of the BP Curves utility without
Light Ends are a good match to the input data. For
example, at 50% the temperature input was 287C versus
the calculated TBP of 285.9C (very close).
QA.7
Chapter 6
Two-Stage Compression
11 Can the values in streams LD1 Out Since both LetDown valve outlets (also the recycle inlets)
and LD2 Out be used as the guess are known, these streams (LD1 Out and LD2 Out) are good
for the Recycle outlet? starting points for the Assumed stream (the guess for the
Recycle).
11 Valve Parameter Comparison:
LD1 Out (Temp, Press, Flow) 42.41C (calc), 1725 kPa, 17.51 kgmole/h (calc)
LD2 Out (Temp, Press, Flow) 38.75C (calc), 3450 kPa, 224.2 kgmole/h (calc)
Is Composition known for LD1 Out? Yes
Is Composition known for LD2 Out? Yes
15 How many iterations did each 1 iterations (RCY-1), 2 iterations (RCY-2)
Recycle need to converge? (Sort by Iteration on Tables page of Monitor tab note the
number of iterations will depend on the starting values,
which will depend on the precise steps and values used to
build the simulation. However, both recycles should
converge with very few iterations).
How close are the Inlet and Outlet Identical or almost identical
stream variables for each Recycle?
Are the Vapour Fractions identical The Vapour Fractions are almost identical for RCY-1 and
for the Inlet and Outlet? RCY-2 (see Recycle Stream Comparison below)
15 Recycle Stream Comparison:
RCY-1 Inlet Vf = 0.1527
Outlet Vf = 0.1527
RCY-2 Inlet Vf = 0.2950
Outlet Vf = 0.2949
29 Are there any unit operations with The Simulation Balance Tool trace window reports Mass
balance errors? Which ones? NOT Balanced. Open the Simulation Balance Tool and
notice the message: Run with Operations Exceeding
Tolerances. Go to the Summary tab for a list of unit
operations with balance errors. The recycle unit operations
have the following balance errors.
RCY-1:
absolute and relative mass errors
relative mole errors
absolute and relative energy errors
absolute component errors (n-Hexane)
RCY-2:
relative mole errors
absolute energy errors
Why do you think these unit These recycles use an iterative numerical method to
operations have balance errors? achieve convergence therefore the solution accuracy
depends on the tolerances specified and the initial
QA.8

estimates.
Can you think of a way to reduce Tightening tolerances. Modify the appropriate sensitivity of
the errors? the Recycle operations on the Adjust/Recycle tab of the
Simulation Balance Tool.
29 Did reducing the sensitivity resolve Yes. Overall Mass Balance Monitor shows Mass Balanced
the balance errors? status indicating that the overall mass balance is satisfied
to within the tolerances specified by the user + SBT should
show no operations exceeding tolerances
How did it achieve this? This was achieved by tightening the tolerances so that the
recycles are converging to a higher accuracy.
34 Outlet pressure of Pipe-100 5900 kPa
42 Exercise 5: First delete the specified adiabatic efficiency and Stage 2
After adding a Compressor Curve Out pressure.
for the Stage 2 Compressor, will the -Open the Stage 2 Compressor view and go to the Curves
existing Compressor be able to page on the Rating tab
achieve the outlet pressure desired -Click the Add Curve button and enter the Speed, Flow,
(6900 kPa)? Head and Polytropic Efficiency data provided in Exercise 5
-Close the window
Will the addition of a third stage of -Select Polytropic Efficiency
compression be required? -Check Activate for the added curve and also
-Check Enable Curves for SS
-Click the Plot Curves button to view the operating point
within the curve
Stage 2 Out pressure = 6595 kPa
The existing compressor was not able to achieve the
desired outlet pressure of 6900 kPa and the addition of a
third stage of compression is required.
Perhaps with a faster compressor speed the desired outlet
pressure could be achieved, however we do not have other
compressor curves to run.
42 Challenge: Looks like your boss is right! Only one recycle block is
Can you reduce your convergence needed in this flowsheet, at the inlet to the IS Sep. Having
time by eliminating one of the a single recycle block at the inlet to the IS Sep allows for
recycle unit operations? both recycle streams to be converged. The Recycle
Assistant also advises this recycle location and the deletion
of the old ones.
Chapter 7
Acid Gas Sweetening w/ DEA
9 Flow rate of water in stream FWKO 14.32 kgmole/h
11 Concentration of H2S and CO2 in H2S = 0.0000
the Sweet Gas stream CO2 = 0.001583
Note that for gas streams concentration almost always
refers to mole fraction.
QA.9

15 Flow rate of stream Makeup H2O 0.7075 kgmole/h
(After closing the recycle loop this becomes 5.453
kgmole/h)
20 CO2 vol% in the Sweet Gas 0.1708 vol%
Note that for gas streams vol% does not refer to liquid
vol%. For gas streams volume fraction = mole fraction,
and thereby to calculate vol% multiply mole frac by 100.
CO2 (mole frac) = 0.001708
CO2 (vol%) = 0.001708*100 = 0.1708
H2S vol ppm level in the Sweet Gas 0.2391 vol ppm
Recall that volume fraction = mole fraction for gas
streams. The vol ppm of H2S can be calculated by either:
1. Multiplying the mole fraction of H2S by 1e6 using a
spreadsheet, OR
2. Changing the basis to mole flow which will display
more significant figures, then calculate:
(H2S mole flow/Total mole flow)*1e6
Have the following pipeline Yes, the pipeline specifications have been met:
specifications been met? CO2: 0.1708 vol% < 2 vol%
Less then 2 vol% CO2 H2S: 0.2391 ppm (volume) < 4 ppm (volume)
Less than 4 ppm (volume) H2S
23 Exercise 1: More gas to the plant requires more amine.
What changes are necessary in the -Double the flow rate of the Sour Gas (feed) stream
simulation to double the flow rate of -Double the amines recirculation rate (Std Ideal Liq Flow)
gas to the plant? in streams DEA to Cool and DEA to Contactor
-Double the Regenerator Reboiler Duty specification on the
Monitor page of the Design tab, since more amines require
more energy to regenerate. This is a very simple approach
and likely could be optimized.
QA.10
Chapter 8
Natural Gas Dehydration w/ TEG
8 What is the Vapour Fraction of 0.9999
Stream Gas+H2O? (it should be
less than 1.0 to ensure saturation)
9 How much water is removed by the 1.279 kg/h
Separator? Read from the FWKO stream
What is the Hydrate Temperature of 18.14C

Stream Gas to Contactor? Add a Hydrate Formation Utility to the stream
12 Flow Rate of Stream Makeup TEG 3.185e-003 kgmole/h
(After closing the recycle loop this becomes 5.368e-004
kgmole/h)
16 Hydrate Temperature of the Sales -10.50C
Gas stream Add a Hydrate Formation Utility to the stream
How does the Hydrate Temperature Gas to Contactor stream Hydrate Temperature = 18.14C
of the Sales Gas stream compare Sales Gas stream Hydrate Temperature = -10.50C
with the Hydrate Temperature of The Sales Gas stream Hydrate Temperature is much lower
the Gas to Contactor stream? than that for the Gas to Contactor stream. Hydrate will not
form until a lower temperature for the Sales gas stream
since the water in this stream has been removed by the
TEG Contactor operation.
The higher the amount of water in a stream, the greater
the probability that hydrate will form near normal
operating temperatures. By removing the water (with
TEGlycol for example) the temperature at which hydrate
forms is lowered, potentially out of operating temperature
range, and averting problems in the pipes.
19 What is the water dew point Sales Gas stream:
temperature of the Sales Gas water dew point temperature = -13.89C
stream? pressure = 6155 kPa
Does it meet the required spec: The Sales Gas stream meets and exceeds the required
-10C (-14F) at 6155 kPa (900 spec.
psia)?
20 Exercise 1: Yes, the TEG concentration increases in the Regen Bttms;
SG to Regen enters as a feed to the from 0.9266 to 0.9985
Regenerator Reboiler. Does the TEG Less water in the Sales Gas stream results in improved
concentration in Regen Bttms TEG recovery in the Regen Bttms stream.
increase?
QA.11

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Process Simulation Fundamentals

Process Modeling using

2013 Honeywell All rights reserved.

Copyright Honeywell 2013. All rights reserved.

2013 Honeywell All rights reserved.

Inside the Current Fluid Packages group, there are a number of

Defining the Simulation

3. Scroll down the list and select the Peng-Robinson Equation of

You can select the

4. Change the Name from the default Basis-1 to GasPlant using

6. Select the following library components, using one of the

7. Click on the Hypo Components\Traditional item in the Add

When you click the

UniSim Design always

Since you do not know the structure of the hypothetical component

13. Add the hypo component to the Selected Components list by

Every hypo you create is part of a Hypo Group. By default, this

Compare the properties of C7+ with C7 and C8.

15. Click the Export button.

UniSim Design will

Building the Simulation

Select a Unit Set

3. Select the SI unit set.

Adding a Stream from the Menu

2. Highlight the Stream Name cell. Change the stream name by

Entering Stream Compositions

3. If the Input Composition for Stream view is not already

The Normalize button

For this component... Enter this mole fraction...

Adding a Stream from the

For this component... Enter this mole fraction...

3. Click the OK button to close the Input Composition for

Adding a Stream from the Object

For this component... Enter this mole fraction...

4. Click OK to close the Input Composition for Stream view.

Save your case!

Changing Units for a

You can scroll through

Perform a P-T flash calculation on the stream GasWell 2. Set the

To use the... Do this...

Next, you will add a utility using each method of installation.

Adding a Utility from the Stream

By default the phase Pressure - Temperature

1. Open the Stream property view for GasWell 2 by double-

3. Click the Create button. The Available Utilities view appears.

4. Select Envelope Utility. Click the Add Utility button. The

6. Switch to the Performance tab to view the phase envelope.

Numerical values can

4. Click the Select Stream button and select stream GasWell 2.

11. On the Design tab, click on Dep. Prop.

Analyzing the Results

5. Go to the Properties page. This page contains more

6. Close the worksheet for GasWell 3.

2. From the Workbook menu, select Setup. The Setup view

The Workbook menu

4. Select Stream and click OK.

11. When complete close the Setup view to return to the

Printing Stream &

Printing the Workbook Datasheet

Printing an Individual Stream

Finishing the Simulation

Save your case!

Critical Point for GasWell 1.